Automated food processing system and method

ABSTRACT

An automated food processing system and method is provided that allows food to be dispensed, fried and packaged in a suitable container, which may be an individual portion-sized container. In one embodiment, the system includes separate automated modules for dispensing, frying and packaging the food.  
     In one embodiment, an automated dispensing device dispenser a predetermined portion of food from a bulk storage container or a food dispensing magazine. Food is dispensed from the automated dispensing device to an automated fry device that can include at least one circular fry wheel having a plurality of food containing compartments. After the food is fried it is dispensed from the fry device to an automated packaging device. The automated packaging device dispenses food to a container that may be an individual portion-sized container that is retrieved, erected and filled by an automated container handling and filling system. After a food container is filled, an automated device transports the filled container to a suitable pick-up location.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. applicationSer. Nos. 10/127,202, 10/127,203, 10/127,309, 10/127,311, 10/127,369,10/127,390, 10/127,398, and 10/127,400, all filed on Apr. 22, 2002.

FIELD OF THE INVENTION

[0002] The invention relates to automated food processing. Moreparticularly, the invention relates to automated food dispensing, fryingand packaging into individual portion-sized containers such as at aquick-service type restaurant.

BACKGROUND OF THE INVENTION

[0003] In restaurants, especially quick service (fast food) restaurants,fast, consistent, efficient and safe food preparation is essential for asuccessful operation. The quality of the prepared food depends in largepart on the consistency of food preparation. The food must be cookedunder correct conditions for the proper time.

[0004] Consistency in food preparation can vary as a result of manyfactors. For example, people engaged in food preparation often mustperform multiple tasks at frequencies that vary with time because ofconstantly varying customer demand throughout the day. For example,lunchtime and dinnertime may be extremely busy while other periods maybe relatively slow. The product mix can vary from hour to hour and dayto day. As a result, the consistency and quality of food may vary.Difficulties in proper scheduling of food production during peak andnon-peak periods can cause customer delays and/or stale, wasted orunusable food.

[0005] Food preparation can be labor intensive, and thus, the labor costcan be a large portion of the total cost of the prepared food. Anadditional problem is that in sparsely populated and other areas wherequick service restaurants are located, such as along interstatehighways, for example, recruiting sufficient numbers of suitableemployees is difficult.

[0006] Quick service restaurants must be able to effectively meet avariable customer demand that is time dependent and not subject toprecise prediction. As a result, stores relying totally on humanoperators will at times be overstaffed and at other times beunder-staffed. Also, problems and potential problems can exist inrestaurants where people directly prepare food. Health and safetyconcerns can also be present where food is prepared directly by people.By reducing or minimizing human contact with food and food cookingequipment, health and safety concerns can also be reduced or minimized.For example, in the frying of foods, some type of hot fluid, such ascooking oil or shortening must be utilized. The cooking temperaturesrequired can present a concern for health and safety.

[0007] Although quick service restaurants have existed for many yearsand now number in the tens of thousands, such establishments utilizemanual labor to prepare and process food. While there have been variousimprovements in commercial equipment used for cooking food in quickservice restaurants, such restaurants are believed to be substantiallyall manually operated and relatively labor intensive.

[0008] Accordingly, a need exists for an automated, commerciallysuitable food dispensing, cooking and packaging device, system andmethod for fried foods that can be operated with a minimum of humanintervention, control and maintenance. More particularly, a need existsfor an automated device, system and method that is capable of, withouthuman labor, frying various food products in desired quantities, such asFrench fries, seasoning the cooked food and packaging the cooked food inindividual portion-sized containers.

SUMMARY OF THE INVENTION

[0009] In accordance with the present invention, an automated foodprocessing system and method is provided. The automated food processingsystem and method in accordance with the invention allows food to bedispensed, fried and packaged in a suitable container or alternativelydispensed to a food holding area for subsequent processing by a humanoperator.

[0010] In accordance with one aspect of the present invention, anautomated module system for dispensing, frying and packaging food intoindividual portion-sized containers is provided. In one embodiment, anysuitable automated dispensing device can be used. In another embodiment,the system includes an automated dispensing module capable of dispensinga desired quantity of food to be fried, an automated fry module adjacentthe dispensing module to receive and fry the quantity of food dispensedfrom the dispensing module and to produce and dispense a quantity offried food and an automated packaging module adjacent the fry module toreceive and package the fried food from the fry module into anindividual portion-sized container.

[0011] Advantageously, in one embodiment, the three modules areindependent from each other and can be operated independently. Plus, inone embodiment, any one of the modules can be deactivated and a humanoperator can manually perform the function of the deactivated modulewith manually operated equipment.

[0012] In accordance with another aspect of the invention, optionally anautomated seasoning device is present to apply seasoning to the food.

[0013] Typically, the automated dispensing module in accordance with theinvention in one embodiment is capable of dispensing one or more ofuncooked or unheated French fries, chicken nuggets, hash browns, chickenpatties and fish filets or similar types of food items to be cookedand/or heated.

[0014] In accordance with another aspect of the invention, the automateddispensing module includes a freezer, a storage container located in thefreezer for containing food to be dispensed, structure for dispensing apredetermined quantity of food from the storage container into asecondary or dump container, with the structure for dispensing and thesecondary or dump container being located in the freezer, and structurefor dispensing the quantity of food from the secondary or dump containerto a location outside of the freezer.

[0015] In accordance with another aspect of the present invention, thefry module of the automated modular system includes a fry vat forcontaining and heating cooking oil, at least one circular fry wheelhaving at least a generally circular perimeter in a plurality ofcompartments, each compartment having an opening towards the perimeter,the fry wheel mounted for rotational movement relative to the radialaxis of the fry wheel, which radial axis is disposed above the normaloperating level of the frying oil or the cooking oil in the fry vat. Adrive mechanism is provided for rotating the fry wheel. In one aspect ofthe invention, any suitable type of automated fry device can beutilized.

[0016] In accordance with another aspect of the present invention, acontrol system is provided for causing the drive mechanism toperiodically rotate the fry wheel back and forth through a relativelysmall amount of angular rotation (such as about 2-10°, for example) tosimulate shaking of a fry basket. Such control can be accomplishedelectronically by devices known to those skilled in the art.

[0017] In another embodiment, food is delivered from the fry module to acooked food holding device, which can comprise a heated holding bin orbins.

[0018] In accordance with still another aspect of the present invention,the automated packaging module includes a rotatable food dispensingmember having an inlet location to receive a quantity of cooked food ata discharge location to discharge cooked food, the packaging module alsoincluding a food dispensing chute position to receive cooked food fromthe discharge location of the rotatable food dispenser, the fooddispensing chute having a discharge location.

[0019] In accordance with another embodiment of the invention, theautomated modular system further includes a carton holding device forholding the individual portion-sized carton or container in position toreceive food from the discharge location of the dispensing chute. Thepackaging module may further include a rotatable food collecting memberdisposed to collect food from the discharge location of a dispensingchute that is not deposited into the individual portion-sized foodcontainer. The so collected food may be subsequently deposited into thefood dispensing chute for delivery to a container or alternatively tothe rotatable food dispensing member or to a waste receptacle or chute.

[0020] In accordance with another aspect of the invention, the automatedpackaging device includes a conveyor system for transporting filledindividual portion-sized food containers from adjacent the fillinglocation to a filled food container holding area, for subsequent pick-upby a human operator, for example. In one embodiment, any suitableautomated packaging device can be utilized.

[0021] In accordance with another aspect of the present invention, anautomated food carton-retrieving device is provided for retrieving andgrasping individual portion-sized food containers. The automatedretrieving device comprises a movable member for selectively graspingand releasing the food container. In one embodiment, the retrievingdevice is capable of grasping and releasing an unerected food containeron one side and the device further includes a second device forselectively grasping the unerected food container on the other side withstructure for moving the retrieving device and the second devicerelatively apart when grasping the sides of the container to erect orpartially erect the container.

[0022] In another embodiment, an automated urging structure is providedfor urging the container bottom upwardly relative to the sides of thecontainer when the sides of the container are moved relatively apart.

[0023] In accordance with another aspect of the invention, the automatedmodular system includes an electronic control system that receivescurrent customer order information and the electronic control systemcauses the selection of a container from a plurality of differentcontainer sizes and further causes filling of food with the size of foodcontainer in response to a customer order. In one aspect, the electroniccontrol system can receive customer order information and controls thedispensing rate of food dispensed from the food dispensing module to thefry module which dispensing automatically determines the amount of foodbeing fried without further intervention by the electronic control. Inone aspect, the control system can include a separate control system foreach of the dispensing, fry and packaging systems or modules, each ofwhich interface with a central control system, which in turn optionallyinterfaces with a POS (point-of-sale) system.

[0024] In accordance with another aspect of the invention, the automatedmodular system is suitable for dispensing, frying and packaging Frenchfries into individual portion-sized containers.

[0025] In accordance with another aspect of the present invention, anautomated method of dispensing, frying and packaging food intoindividual portion-sized containers is provided that includes dispensinga desired quantity portion of food to be fried from an automateddispensing module to an automated fry module and thereafter frying theportion of food dispensed from the dispensing module in the automatedfry module adjacent the dispensing module to produce a quantity of friedfood. Thereafter, the quantity of fried food is dispensed from the frymodule to a packaging module where the fried food dispensed from the frymodule is packaged into individual portion-sized containers with anautomated packaging module.

[0026] In another aspect of the invention, the automated method furthercomprises seasoning the quantity of fried food with a seasoning device.

[0027] In accordance with another aspect of the invention, thedispensing includes dispensing a predetermined quantity of food from thestorage container into a secondary container located in a freezer anddispensing the quantity of food from the secondary container to alocation outside of the freezer.

[0028] In accordance with another aspect of the method of the presentinvention, the frying comprises a rotating fry wheel having at least agenerally circular perimeter and a plurality of compartments, eachcompartment having an opening towards the perimeter, the food beingcontained in at least one of the compartments during the frying, the frywheel being mounted for rotational movement relative to the radial axisof the fry wheel in a fry vat with the radial axis being disposed abovea normal operating level of the cooking oil in the fry vat. Inaccordance with this aspect of the invention, the automated methodfurther includes containing a drive mechanism to periodically rotate thefry wheel back and forth through a relatively small amount of angularrotation to simulate shaking of a fry basket during frying.

[0029] In accordance with another aspect of the invention, the packagingincludes rotating a rotatable food dispensing member having an inletlocation to receive a quantity of cooked food in a discharge location todischarge cooked food, the food dispensing member being rotated todispense food into a food dispensing chute position to receive cookedfood from the discharge location of the rotatable food dispenser andthereafter dispensing said food from the dispensing chute to a containerto be filled.

[0030] In accordance with another aspect of the invention, the methodfurther includes holding an individual portion-sized carton or containerpositioned to receive food from the dispensing chute with an automatedcarton holding device.

[0031] In accordance with still another aspect of the invention, themethod further includes collecting food dispensed from the dischargelocation of the dispensing chute that is not deposited into theindividual portion-sized food container with a rotatable food collectingmember disposed to collect such not deposited food.

[0032] In accordance with another aspect of the method, the methodincludes electronically coordinating the operation of the three modulesor devices within an electronic control system. In one embodiment, themethod further includes electronically receiving current customer orderinformation by the electronic control system which causes selection of acontainer from a plurality of different sized containers and filling thecontainer with food of the ordered size of food container in response toa customer order by the packaging module. In accordance with anotheraspect of the method, customer order information is electronicallyreceived and the dispensing rate of food dispensed from the fooddispensing module to the fry module is controlled, which dispensingautomatically determines the amount food being fried without furtherintervention by the electronic control system.

[0033] In accordance with another aspect of the present invention, anautomated dispensing device for dispensing a quantity of food to besubsequently cooked is provided. In one embodiment, the automateddispensing device includes a freezer or refrigerated compartment, astorage container located in the freezer for containing food to bedispensed, structure for dispensing a predetermined quantity of foodfrom the storage container into a secondary or dump container, thestructure for dispensing the predetermined quantity of food beinglocated in the freezer, and structure is provided for dispensing thequantity of food from the secondary or dump container in the freezer toa location outside of the freezer.

[0034] In one embodiment, the structure for dispensing a predeterminedquantity of food includes a vibratory conveyor typically located in thefreezer below the storage container. The structure for dispensing mayfurther include a device for determining or sensing the quantity of foodthat has been deposited in the secondary container and structure isprovided for terminating the operation of the structure for dispensingwhen a predetermined quantity of food is sensed in the secondarycontainer.

[0035] In accordance with another aspect of the present invention, thesecondary container has a bottom that is at least partially open and thesecondary container is movable laterally between a filling positionlocated within the freezer and a dispensing position for dispensing foodthrough the container open bottom and out of the freezer. The secondarycontainer may include a floor member that is located below the containerhaving the at least partially open bottom. The floor member and thecontainer are movable relative to each other between the first andsecond positions wherein in the first position the floor member isadjacent the open bottom and prevents food from being dispensed from thecontainer and when in the second position food is free to fall throughthe open bottom of the container.

[0036] In one embodiment, a device for determining the quantity of foodlocated in the second container is provided with structure forterminating the operation of the structure for dispensing food into thesecond container when a predetermined quantity of food is sensed in thesecondary container. The device for determining the quantity may be on avolume or weight basis and thus can be a weighing mechanism, which canbe a load cell. In one embodiment, a device is provided for moving thesecond container laterally sufficiently to the dispensing position sothat food contained therein is dispensed. Such a device may be, forexample, a suitable actuator, which can be an air or hydraulic cylinder,for example. In one embodiment, the automated dispensing device furtherincludes a door that is located over an opening in the freezercompartment and positioned relative to the secondary container so thatwhen the secondary container is moved laterally to the dispensingposition, the food in the secondary container exits the freezercompartment through the open bottom and through the freezer compartmentopening. Typically, the dispensed food will then be directed into thefry module.

[0037] In accordance with another aspect of the present invention, avibratory conveyor is provided for conveying food items to the secondarycontainer. The vibratory conveyor in one embodiment may have aserpentine or a zigzag food travel pathway.

[0038] In accordance with another aspect of the invention, the tray forvibratory conveying of food articles from a hopper may include a traybody, a food inlet portion and a food outlet portion, the food inletincluding an upwardly extending dividing member for dividing the trayinto at least two food inlet conveyor passageways, the inlet conveyorpassageways merging into a single food passageway that extends to thefood outlet portion after which the food passing therethrough isdispensed into the secondary container. In one embodiment, the singlefood passageway may be nonlinear and may have a zigzag or a serpentinepathway or configuration. In one aspect of the invention, the dividingmember of the tray for vibratory conveying of food articles issaddle-shaped. The tray for vibratory conveyance of food articles can beconfigured and dimensioned so that the single food passageway causesfood of a particular size, such as the size of chicken nuggets, forexample, to be conveyed in a single file arrangement. This allows for aprecise vibratory dispensing of the food articles permitting them to bedispensed one at a time from the vibratory conveyor to the secondarycontainer. Such an arrangement permits accurate metering of the foodarticles and precise control of the batch sizes that are cooked andsubsequently packaged and served to customers. This permits moreeconomical and efficient and reproducible operations.

[0039] In accordance with another aspect of the present invention, thevibratory conveyor includes a tray that has a bottom portion with aplurality of spaced apart holes to permit relatively small undesirableparticles, such as ice particles and small particles of food to passtherethrough so that such material is not dispensed into the secondarycontainer. To accomplish this, typically the holes will be less thanabout 0.25 inches in diameter and can be located in a suitable array asdesired.

[0040] In accordance with another aspect of the invention, a generallyvertically extending declumping member is provided that can interactwith food contained in the vibrating conveyor. Preferably, thedeclumping member is in the form of a cylindrical member or pin thatextends generally vertically towards the vibrating conveyor from aposition located above the vibrating conveyor. Typically, the declumpingmember will be stationary relative to the vibrating conveyor so that asfood, in particular, such as French fries, pass the declumping member asthey travel along the vibrating conveyor clumps of French fries can beseparated into smaller clumps or individual French fries. Thisfacilitates the subsequent frying of such food materials.

[0041] In accordance with another aspect of the present invention, theautomated dispensing device includes structure for dispensing apredetermined quantity of food that comprises a food magazine capable ofdispensing individual pieces of food on a piece by piece basis. Inaccordance with a more specific aspect of this embodiment, the magazinecomprises dual rotatable spiral flights with the spiral flights having aspacing therebetween to allow placement of a food item, such as achicken patty, for example, to be supported by both spiral flights.

[0042] In accordance with another aspect of the invention, the magazinedispenser is suspended from a slide mechanism permitting removal of themagazine from the freezer or refrigerated compartment. A plurality ofthe magazines can be located on a single slide mechanism. An array ofthe magazines may be located in the freezer, such as a 3×5 array or a3×4 array, for example.

[0043] In one embodiment, a separate drive motor is associated with eachfood dispensing magazine for selectively rotating spiral flights of amagazine dispenser for dispensing a desired number of the food items.The drive motor may also be located in the freezer.

[0044] In accordance with another aspect of the invention, an automatedmethod of dispensing a quantity of food to be cooked is provided. Themethod includes storing food items in a storage container located in thefreezer, dispensing food items from the storage container to a conveyor,conveying the food items on the conveyor to a secondary or dumpcontainer located in the freezer, monitoring the amount of food itemsdelivered to the secondary container, terminating delivery of the fooditems to the secondary container when a desired amount of food items aredetermined to be present in the secondary container as determined by themonitoring, and dispensing the food items from the secondary containerand out of the freezer by at least partially inverting the secondarycontainer. In accordance with another aspect of this embodiment, afreezer or refrigerated compartment is not utilized.

[0045] In accordance with another aspect of the present invention, themethod includes storing food items in a storage container, dispensingfood items from the storage container to a conveyor, conveying the fooditems on the conveyor to a secondary container having at least apartially open bottom with a floor member adjacent the open bottom,monitoring the amount of food items delivered to the secondarycontainer, terminating delivery of the food items to the secondarycontainer when a desired amount of food items are determined to bepresent in the secondary container as determined by said monitoring anddispensing the food items from the secondary container and through theopen bottom of the secondary container by relative movement of the floormember to the open bottom of the container.

[0046] The conveying may comprise vibratory conveying, as desired.

[0047] In one embodiment, the secondary container with the at leastpartially open bottom moves relative to the floor member that remainsstationary.

[0048] In accordance with another aspect of the present invention, adevice for the automated frying of foods is provided. The device in oneembodiment includes a fry vat for containing and heating cooking oil, atleast one circular fry wheel having at least a generally circularperimeter and a plurality of compartments with each compartment havingan opening towards the perimeter, the fry wheel mounted for rotationalmovement relative to the radial axis of the fry wheel which radial axisis disposed above the normal operating level of the frying oil in thefry vat. A drive mechanism is provided for rotating the fry wheel and acontrol system is included for causing the drive mechanism toperiodically rotate the fry wheel back and forth through a relativelysmall amount of rotation (such as about 2-10°, for example) to simulateshaking of a fry basket. Such control can be accomplished electronicallyby devices known to those skilled in the art.

[0049] In accordance with another aspect of the present invention, thesmall amount of rotation is-in the range of from about 2° to about 20°.The back and forth rotation in one direction may be of a larger angle oramount of rotation than of the rotation in the other direction.

[0050] In one embodiment, a control system is provided that causesperiodic incremental rotation of the fry wheel in one direction to causefood deposited into one of the compartments to travel through thecooking oil in the fry vat over a period of time to fry the food and tomove the compartments out of the cooking oil for subsequent discharge ofthe food from the compartment. In one embodiment, the periodicincremental rotation is based on 360° divided by the number ofcompartments in the fry wheel.

[0051] In accordance with another aspect of the present invention, acontrol system is provided for operating the drive mechanism to rotatethe fry wheel in one direction to cause food deposited into one of thecompartments to travel through the cooking oil in the fry vat over aperiod of time to fry the food and out of the cooking oil for subsequentdischarge of the food from the compartment, wherein the control systemadjusts the speed of rotation based on the level of cooking oil in thefry vat. In one embodiment, the control system causes incrementalperiodic rotation of the fry wheel and the control system adjusts theperiod of time between incremental rotations based on the level ofcooking oil sensed in the fry vat. The period of time betweenincremental rotations can also be based on the temperature of thecooking oil in the fry vat.

[0052] In accordance with another aspect of the invention, a curvedbaffle is provided that is disposed in the fry vat adjacent the axialperiphery of the portion of the fry wheel that is disposed in thecooking oil for preventing food contained in one or more of the frywheel compartments from falling out of the compartments.

[0053] In accordance with another aspect of the invention, a device forthe automated frying of food is provided that includes a fry vat forcontaining and heating cooking oil, at least one circular fry wheelhaving at least a generally circular perimeter and a plurality ofcompartments each having an opening towards the perimeter, the fry wheelmounted for rotational movement relative to the radial axis of the wheelwhich radial axis is disposed above the normal operating level of thefrying oil in the fry vat, a drive mechanism for rotating the fry wheeland an overflow passageway having an inlet that is located above thenormal operating level of the frying oil in the fry vat. Preferably, theoverflow passageway is located in a foam deck that is adjacent a side ofthe fry vat. The foam deck has a surface located above the normaloperating level of the frying oil in the fry vat. In one embodiment, theoverflow passageway comprises an elongated slot in the foam deck. Thefoam deck is preferably located adjacent or in proximity to the foodinlet location for supplying a quantity of food to be fried in the frywheel.

[0054] In accordance with another aspect of the present invention, anautomated method of frying food in a fry vat having a heated cooking oilcontained therein is provided. The method includes placing food in a frywheel compartment, each of the compartments having an opening towardsthe perimeter of the fry wheel, rotating the fry wheel so that thecompartment containing the food travels submerged in the heated cookingoil and periodically rotating the fry wheel back and forth in arelatively small amount of rotation to simulate shaking of the frybasket while the food is submerged in the cooking oil. In accordancewith another aspect of the method of the present invention, the methodcomprises rotating the fry wheel in one direction to cause the fooddeposited into one of the compartments to travel through the cooking oilin the fry vat over a period of time to fry the food and to move thefood out of the cooking oil for subsequent discharge of the food fromthe compartment, wherein the speed of said rotating is related to thelevel of cooking oil in the fry vat. In accordance with this aspect ofthe present invention, the rotating may comprise incremental periodicrotation with the period of time between incremental periodic rotationsbeing based on the level of cooking oil sensed in the fry vat. Theperiod of time between incremental periodic rotations may also be basedon the temperature of the cooking oil in the fry vat.

[0055] In accordance with another aspect of the invention, an automatedmethod of frying food is provided that includes placing food to be friedin a fry wheel compartment of a fry wheel having at least a generallycircular perimeter and a plurality of compartments, each having anopening towards the perimeter, the fry wheel mounted for rotationalmovement relative to the radial axis of the wheel which radial axis isdisposed above the normal operating level of the frying oil in a fry vathaving heated cooking oil therein, providing an overflow passagewayhaving an inlet that is located above the normal operating level of thefrying oil in the fry vat, collecting in the overflow passageway atleast some of the water containing foam that results when food to befried and placed in the fry wheel contacts the frying oil and rotatingthe fry wheel so that the compartment containing the food travelssubmerged in the heated cooking oil. The method may further includeperiodically rotating the fry wheel back and forth with a relativelysmall amount of rotation to simulate shaking of a fry basket while foodis submerged in the cooking oil.

[0056] In accordance with another aspect of the present invention, anautomated method of packaging cooked food, which may be food such asFrench fries, chicken nuggets and other types of food, in an individualportion-sized container is provided. The method includes delivering aquantity of a cooked food to a rotatable dispensing member, rotating thedispensing member to cause the food items to fall from one or morecompartments of the dispensing member into a food dispensing chute andthereafter dispensing the food from the chute and depositing the foodinto the individual portion-sized food container.

[0057] In accordance with one aspect, the method may further includeweighing the food in the chute before dispensing the food to thecontainer.

[0058] In accordance with another aspect of the invention, the methodincludes applying seasoning to the food and may further include applyingthe seasoning by using gravity to cause the seasoning to travel througha nozzle and onto the food.

[0059] In accordance with another aspect of the invention, the methodfurther includes shaking the individual portion-sized food containerafter the dispensing. The shaking may be automated and can include backand forth movement of the container through an arc as desired, and maybe in a generally vertical axis. The arc may be a generally circular arcand the rotating back and forth may encompass an arc in the range offrom about 3° to about 20°. In addition, the container may be raised andlowered before, during or after the rotating to further simulate shakingor in connection with further container handling.

[0060] In accordance with another aspect of the invention, whendispensing food from the chute to the individual portion-sizedcontainer, some of the dispensed food is not deposited into theindividual portion-sized container and the method further includescollecting the not deposited food. Typically, the not deposited foodwill be collected in a collection device that returns the not depositedfood to the chute for subsequent dispensing. In one embodiment, thecollection member is rotatable and can be rotated to deposit thecollected food to the chute. This helps to ensure that the not depositedfood is subsequently deposited into a container on a first-in, first-outor a generally first-in, first-out basis.

[0061] In accordance with another aspect of the present invention, anautomated method of packaging food, including food such as French fries,in an individual portion-sized container is provided that includesdelivering a quantity of food to a food dispensing chute, selecting andholding with an automated device an individual portion-sized containerof a desired size from a plurality of different sizes of individualportion-sized containers that can be selected and held by the automateddevice. The selected individual portion-sized container is moved by theautomated device to a location for receiving food from the dispensingchute and food is dispensed from the chute and into the container. Themethod may further include depositing the filled food container onto aconveyor by operation of the automated device and transporting thedeposited container by the conveyor to a human operator food pickuplocation.

[0062] In accordance with another aspect of the foregoing method, theindividual portion-sized food container is unerected and the methodfurther includes after the selecting, erecting the selected individualportion-sized food container by the automated device. In one embodiment,the automated device includes a partial vacuum suction device forholding the individual portion-sized food container and the holdingincludes applying a partial vacuum through a suction device to the foodcontainer. The food container can be released by reducing or eliminatingthe vacuum applied by the suction device to the food containersufficiently to cause the food container to be disengaged from theautomated device.

[0063] In accordance with another embodiment of the method, the filledfood container is placed in an upright position on a transportablemember or container-receiving receptacle which in one embodimentcontains a single food container and is maintained in an uprightposition on the transportable member by cooperation of the recessedvolume of the transportable member and the food container.

[0064] In accordance with another aspect of the invention, thetransporting is performed by a magnetic conveyor.

[0065] In accordance with another aspect of the invention, an automatedmethod of packaging cooked French fries in individual portion-sizedFrench fry containers is provided. The method includes delivering with amechanical device cooked French fries to a French fry holding bin andmechanically scooping with a mechanical device an open French frycontainer into the cooked French fries in the holding bin to fill theFrench fry container with French fries. After filling the French frycontainer, the method further includes mechanically depositing thefilled French fry container at a drop-off location. Typically, thedrop-off location will include a location that is convenient for a humanoperator to access the filled French fry containers for subsequentservice to a customer.

[0066] In accordance with this aspect of the invention, typically thedelivering of cooked French fries to a French fry holding bin will beaccomplished by receiving the French fries from an inlet chute whichchute is traversed by the French fries prior to entering the French fryholding bin. When used with a fry module in accordance with theinvention or some other type of fry apparatus including a manual fryoperation, the French fries enter the inlet chute after being dispensedfrom the fry module or other arrangement.

[0067] The automated method of packaging cooked French fries may furtherinclude applying seasoning to the French fries which may occur while onthe inlet chute. The application of seasoning is preferably done by anautomated system which may include a seasoning device or a saltingdevice as hereafter described in detail.

[0068] In accordance with another aspect of the invention, the inletchute includes structure for vibrating the inlet chute to facilitatetransport of French fries down the inlet chute.

[0069] In one embodiment, the inlet chute includes a first gate that ismovable to a position that restrains the French fries from travellingdown the chute. This provides a convenient time during which to applythe desired seasoning to the French fries. The gate may include aplurality of reciprocable fingers that are configured for up and downmovement. The fingers may be configured such that in a retractedposition the fingers do not extend above the surface of the inlet chuteand in an extended position the fingers extend outwardly above thesurface of the inlet chute sufficiently to prevent the passage of Frenchfries. In addition, in one embodiment, the fingers are periodicallyreciprocable in an up and down direction so that the fingers have adeclumping action on French fries passing through the chute at thelocation of the reciprocable fingers.

[0070] In accordance with another embodiment of the invention, themethod includes further restraining the French fries from exiting theinlet chute at a location downstream of the gate after passing the firstgate. The further restraining can be performed by a second gate locateddownstream of the first gate. Preferably, when utilized, the second gatewill be located downstream of the first gate a sufficient distance sothat a desired quantity of French fries can be stored on the chutebetween the first and second gates. The second gate can be moved to aposition that does not restrain the French fries so that the Frenchfries are free to travel into the holding bin.

[0071] In accordance with another aspect of the automated method ofpackaging cooked French fries, the method further includes mechanicallyshaking the filled individual portion-sized French fry container priorto the depositing. The shaking may include back and forth movementthrough an arc in which the end-of-arm tool of the mechanical devicetravels, thereby causing the filled individual portion-sized French frycontainer to travel in that arc which can be any generally verticalaxis. In accordance with one embodiment, the mechanical device is amechanical arm which can perform the mechanical scooping, shaking anddepositing steps as desired. In addition, the method may further includeholding the individual portion-sized French fry container with amechanical arm of the mechanical device while performing the scooping,shaking and/or depositing. The shaking may be accomplished by up anddown vertical movement of the mechanical arm.

[0072] In accordance with another aspect of the invention, the methodfurther includes mechanically obtaining an unerected individualportion-sized French fry container to be filled from a stack ofunerected individual portion-sized French fry containers. The method canstill further include mechanically erecting the unerected individualportion-sized French fry container prior to the scooping. The method mayfurther include, before the obtaining of the unerected carton, selectingand holding with the mechanical device an individual portion-sizedcontainer of a desired size from a plurality of different sizes ofindividual portion-sized containers that can be selected and held by theautomated device.

[0073] In accordance with another aspect of the present invention, amethod of erecting a collapsed, individual portion-sized French frycontainer of the type having opposed sidewalls connected by acollapsible container bottom is provided. The method includes graspingthe unerected French fry container, pulling the container against arestraining member and mechanically dragging the bottom of the containerso that it traverses up an inclined ramp to urge up the container bottomto urge the container to an erected position. The method may furtherinclude injecting a stream of compressed air into the open end of thecontainer and towards the container bottom for assisting in theerecting.

[0074] As used herein, the term “fill” or “filled” is not limited tocompletely filling or a completely filled container and thus includespartially filling or partially filled containers.

[0075] In accordance with still another aspect of the invention, anautomated device for packaging cooked food into a desired container,which may be an individual portion-sized food container is provided. Thedevice includes a rotatable food dispensing member having an inletlocation to receive a quantity of the cooked food and a dischargelocation to discharge the cooked food. A food dispensing chute ispositioned to receive the cooked food from the discharge location of therotatable food dispenser and the dispensing chute has a dischargelocation. In one embodiment, the dispensing chute has a food holdingarea for holding a quantity of the cooked food deposited therein. Asuitable weighing device can be associated with the dispensing chute toweigh the food that is contained in the chute or in the holding area ofthe chute. In one embodiment, the weighing device is a load cell.

[0076] In accordance with another aspect of the invention, the automateddevice includes a food carton or container holding device for holdingthe food carton in position to receive food from the discharge locationof the dispensing chute. The carton holding device can include anaxially rotatable generally vertically extending elongated first memberand a second member that extends from the elongated member, the secondmember having a gripping member for gripping a food container, which maybe an individual portion-sized food container. In one embodiment, thegripping member comprises a suction cup. A vacuum source may be suppliedto the suction cup to create at least a partial vacuum, allowing thecontainer to be held. In one embodiment, the carton holding device iscapable of moving the food container through an arc of about or of atleast about 180° and in which the carton holding device is capable ofmoving the food container up and down.

[0077] In accordance with another aspect of the present invention, theautomated device comprises a conveyor system for transporting filledindividual portion-sized food containers from adjacent the fillinglocation to a filled container holding area. The conveyor system maycomprise in one embodiment a continuous loop raceway and a plurality ofdiscrete movable food container receptacles that are movable along theraceway. The conveyor system may include a continuous movable loophaving at least one magnetic element capable of magnetically attractingone of the movable receptacles at a time for causing movement of thereceptacle corresponding to movement of the magnetic element. Aplurality of the magnetic elements may be spaced apart along the movableloop.

[0078] In one embodiment, structure is provided for preventing movementof the discrete receptacles when the structure for moving the discretereceptacles along the raceway is activated. The structure for preventingmovement can be a barrier that is disposed across the raceway. In oneembodiment, the barrier is selectively movable and in another embodimentthe barrier is fixed. In one embodiment, the barrier prevents movementof the receptacles only for a receptacle that has a food carton orcontainer disposed thereon. In this embodiment, the barrier may belocated at a height that is above the top of the receptacles located onthe conveyor system adjacent the barrier.

[0079] In accordance with another aspect of the invention, an automateddevice is provided to retrieve and grasp a food container, which may bean individual portion-sized food or French fry container or carton. Theautomated retrieving device includes a member for selectively graspingand releasing the food container and for moving the movable memberhorizontally and linearly.

[0080] In accordance with another aspect of the invention, a magazine isprovided for holding a plurality of food containers in an unerectedstate.

[0081] In accordance with another aspect of the invention, the automateddevice includes a retrieving device that is capable of grasping andreleasing an unerected food container on one side and further includes asecond device for selectively grasping the unerected food container onthe other side. A structure for moving the retrieving device and thesecond device relatively apart when grasping the sides of the containeris provided. The automated device may further include an automatedurging means for urging the container bottom upwardly relative to thesides of the container when the retrieving device and the second deviceare moved relatively apart when grasping the container.

[0082] In accordance with another aspect of the invention, the fooddispensing member is a rotatable wheel having an open central area andan outer at least generally circular rim. The rotatable wheel has aplurality of open compartments spaced apart about the circular rim thatextend inwardly from the circular rim and open interiorly of thecircular rim. A baffle may be provided to prevent food contained in theone or more of the open compartments from falling out of thecompartments when the wheel is rotated until the compartment is inposition over the food dispensing chute. The baffle may be curved tofollow the curvature of the inner part of the wheel and may also beperforated. The automated device may further include a rotatable foodcollecting member that is disposed to collect food dispensed from thedischarge location of the dispensing chute which food is not depositedinto a container held in position at the discharge location. Typically,the collection member will have a discharge location to dischargecollected food. In one embodiment, the discharge location is the fooddispensing chute. The collecting member may be a rotatable foodcollecting wheel having an open central area and an outer circular rimhaving a plurality of open compartments spaced apart about the circularrim that extend inwardly from the circular rim and that are open towardsthe rim interior. The rotatable food dispensing member and the rotatablefood collecting member can be rotatable in one direction to dischargefood at a discharge location and into a food dispensing chute and can berotatable in an opposite direction to discharge the food at a seconddischarge location which may be to a waste chute. The discharge to thewaste chute feature can be activated, for example, when the food is heldin the dispensing device for too long a period of time.

[0083] The packaging device may also include an automated seasoningdevice for depositing a predetermined quantity of seasoning to foodcontained in the packaging device.

[0084] In accordance with another aspect of the invention, the devicefor applying seasoning includes a seasoning delivery tube having aninlet and a discharge location. A seasoning delivery head is positionedto deliver seasoning to the food to be seasoned with the head incommunication with the outlet of the delivery tube and located below theinlet of the delivery tube. Structure is provided for depositing apredetermined quantity of seasoning into the inlet of the delivery tubeso that the quantity of seasoning falls by gravity through the deliverytube and into and through the seasoning head and onto the food to beseasoned. Typically, the structure for depositing the predeterminedquantity of seasoning will receive seasoning from a bulk hopper bygravity feed. The quantity of seasoning to be dispensed can bedetermined volumetrically, for example.

[0085] In accordance with still another aspect of the invention, anautomated device for packaging cooked French fries into an individualportion-sized French fry container is provided. The device includes amechanical arm having an end-of-arm tool capable of picking up andgrasping an erected individual portion-sized French fry carton from anerected carton pick-up location, and scooping the erected carton whileheld by the end-of-arm tool into a quantity of cooked French frieslocated at a filling location to fill the French fry carton andthereafter depositing the filled French fry carton at a drop-offlocation spaced from the filling location. The automated device mayfurther include a French fry holding bin for holding a bulk quantity ofFrench fries at the filling location and a French fry inlet chute forreceiving a bulk amount of French fries. In one embodiment, theautomated device further includes structure for vibrating the French fryinlet chute. In accordance with another aspect of the invention, theautomated device further includes structure for retaining French frieson the French fry chute and may further include structure for applyingseasoning to the French fries contained on the inlet chute.

[0086] In accordance with another aspect of the invention, the structurefor retaining French fries on the chute is composed of a plurality ofvertically reciprocable fingers movable between an extended position forretaining French fries on the inlet chute and a retracted position forpermitting French fries to travel on at least a portion of the chute. Inone aspect, the movable gate may comprise a plurality of spaced apartfingers reciprocable in up and down directions to restrain French friesfrom sliding down the inlet chute when in an up position and fordeclumping French fries when the fingers are reciprocated up and downwhen French fries are travelling past the reciprocating fingers.

[0087] In accordance with another aspect of the invention, the automatedpackaging device may include a movable gate located between thedischarge end of the inlet chute and the holding bin and movable betweena raised position for retaining French fries on the inlet chute and alowered position for permitting French fries to travel from the inletchute to the holding bin.

[0088] In accordance with another aspect of the invention, the Frenchfry holding bin may have a sensing device associated therewith fordetermining whether a desired quantity of French fries are contained inthe French fry holding bin. The sensing device can be any suitabledevice that may be known in the art, such as a weighing device and canbe a load cell, for example.

[0089] In accordance with still another aspect of the invention, aFrench fry carton storage and erection device is provided that includesan automated, unerected French fry carton retrieving device forretrieving and grasping an unerected individual portion-sized French frycontainer. The automated retrieving device includes a grasping memberfor selectively grasping and releasing a French fry container. Theautomated retrieving device may further include structure for linearlymoving the movable member in two dimensions. The two dimensions may begenerally horizontal dimensions and may be composed of one or morecarriages, one for each of the dimensions.

[0090] In accordance with another aspect of the invention, a magazinefor holding a plurality of individual portion-sized French frycontainers in an unerected state is provided. In one embodiment, themagazine is capable of holding a plurality of segregated groups ofindividual portion-sized unerected French fry containers, each group inthe plurality being of a different size container. In one embodiment,the magazine holds each group of unerected containers in a stack, whichmay be in either a generally horizontal or a vertical stack. Thecontainer retrieving device can be positionable to retrieve containersfrom the front of each stack.

[0091] In accordance with another aspect of the invention, the graspingmember comprises a suction device for selectively grasping and releasinga French fry container. The suction device may comprise a suction cuplocated on the grasping member that is capable of grasping and releasingthe French fry container by applying and releasing a vacuum,respectively, that communicates with the interior of the suction cup.

[0092] In accordance with another aspect of the invention, theretrieving device is capable of grasping and releasing a French frycontainer on one side thereof and the automated erecting device furtherincludes structure for erecting an unerected French fry container of thetype having opposed sidewalls connected by a collapsible containerbottom. The automated device for erecting the container includesstructure for urging the container from an unerected to an erectedposition and for urging the container bottom upwardly relative to thesides of the container which will occur typically when the retrievingdevice grasps the container and retrieves the container from the stackof containers. In one embodiment, the structure for urging comprises aninclined ramp while in another embodiment, the structure for urgingincludes an automated retrieving and container grasping device forgrasping one of the opposed sidewalls of the unerected container and arestraining member for restraining from relative movement the other ofthe opposed sidewalls when the one sidewall is grasped by the graspingdevice and moved in a desired direction. In addition, structure may beprovided for injecting a stream of compressed air into the open end ofthe container when the opposed sidewalls are at least partially movedapart from each other to help urge the opposed sidewalls apart to erectthe container.

[0093] In accordance with another aspect of the present invention, theautomated device further includes an elevator for moving an erectedFrench fry container from a first location proximate the unerectedcontainer retrieving device to a second location. The elevator maycomprise a rodless cylinder configured to carry a receptacle or othersuitable structure for holding an erected French fry container with thereceptacle being movable between first and second locations by therodless cylinder. In one embodiment, the second location is proximatethe mechanical arm so that a French fry container in the second positioncan be grasped by the end-of-arm tool.

[0094] In another embodiment of the invention, the mechanical arm of thepackaging module is mounted to a carriage for providing lateral movementof the mechanical arm. The mechanical arm can be configured so that itcan move the end-of-arm tool through a generally vertical compound arcas well as for selectively moving the end-of-arm tool linearly up anddown. In one embodiment, the end-of-arm tool comprises a French fryscoop and further includes a gripping mechanism actuable betweenclamping and non-clamping positions wherein the gripping mechanism cangrasp a French fry container when in the clamping position and releasethe previously grasped French fry container when the gripping mechanismis in the non-clamping position. The gripping mechanism can be capableof grasping one of the opposed sidewalls of an erected French frycontainer. In one embodiment, the gripping mechanism includes afinger-type structure with an actuator device for moving the fingerstructure between the clamping and non-clamping positions. The grippingmechanism can be configured to clamp an upper end of an erected Frenchfry container between the finger structure of the gripping mechanism andthe French fry scoop of the end-of-arm tool.

[0095] In another embodiment of the invention, the mechanical arm of thepackaging module includes a plurality of pivotable links connected inseries. In one embodiment, the mechanical arm includes at least twopivotable links and in another embodiment the mechanical arm includesthree pivotable links. The mechanical arm can be configured so that eachof the links is pivotable in the same or in parallel planes. In oneembodiment, the mechanical arm is mounted to a carriage or othersuitable structure for providing lateral movement of the mechanical arm.Typically, the lateral movement will be in a generally horizontaldirection.

[0096] In accordance with another embodiment, the mechanical armincludes first, second and third links wherein the first link isconnected to a generally horizontally movable carriage, the third linkis connected to the end-of-arm tool and the second link is connected tothe first and third links. A connection of one of each of the links toanother link may comprise a pivot connection and an actuator may beprovided for each pivot connection for pivoting the respective one ofsaid links about the pivot connection which connects that link toanother of the links to cause selective rotation of one link withrespect to another of said links.

[0097] In accordance with another embodiment of the invention, theautomated device further includes a structure for containing a pluralityof French fry cartons that are filled with French fries, the structurehaving at least a portion that is in communication with the drop-offlocation of the mechanical arm. In one embodiment, the structure is arack that can be constructed of any suitable material and configuration.In one embodiment, the rack is inclined in a direction away from themechanical arm so that when the mechanical arm drops off a containerfilled with French fries, the container slides down the rack to aconvenient location for pick-up by a human operator. In anotherembodiment, the structure comprises a rotatable carousel. In accordancewith another aspect of the invention, the mechanical arm is configuredto mimic the motion of a person's arm, wrist and hand action in scoopingFrench fries into a French fry container while grasping the French frycontainer in one hand and moving the French fry container in a verticalarc and scooping the open end of the French fry container through aquantity of French fries and thereafter moving the French fry containerto a generally upright position and shaking it sufficiently to causeloosely contained French fries to fall from the container. Typically,this action occurs with a French fry scoop attached to an upper end ofthe open French fry container as is commonly known in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

[0098]FIG. 1 is a perspective view of an automated food processingsystem in accordance with the invention;

[0099]FIG. 2 is a perspective view of an alternate embodiment of a foodprocessing system in accordance with the present invention;

[0100]FIG. 3 is a schematic view, partly in section, of the foodprocessing system of FIG. 1;

[0101]FIG. 4 is a side elevation view of a portion of a bulk fooddispensing device in accordance with the present invention;

[0102]FIG. 4A is a side elevation view, partly in section, of analternative embodiment for a portion of the dispensing deviceillustrated in FIG. 4;

[0103]FIG. 5 is a top plan view of a portion of the bulk food dispensingdevice in accordance with the present invention;

[0104]FIG. 6 is a side elevation view, partly in section, of a bulk fooddispensing device in accordance with the present invention and alsoillustrating a portion of a device for frying food in accordance withthe present invention;

[0105]FIG. 7 is a perspective view of a magazine-type dispenser that canform part of the food dispensing device of the present invention;

[0106]FIG. 8 is a partial side elevation view of the magazine dispenserof FIG. 7;

[0107]FIG. 9 is a perspective view of a magazine-type dispenser arraythat can be utilized in the dispenser of the present invention;

[0108]FIG. 10 is a fragmentary view of the device of FIG. 9;

[0109]FIG. 11 is a top plan view of a food frying device in accordancewith the present invention;

[0110]FIG. 12 is a front elevation view of the food frying device ofFIG. 11;

[0111]FIG. 13 is a partial fragment sectional view along line 13-13 ofFIG. 11;

[0112]FIG. 14 is a fragmentary sectional view of a portion of the foodfrying device of FIG. 11;

[0113]FIG. 15 is a sectional view along line 15-15 of FIG. 14;

[0114]FIG. 16 is a perspective view of a drive mechanism for the foodfrying device of FIG. 11;

[0115]FIG. 17 is a fry basket for use in the frying device of FIG. 11;

[0116]FIG. 18 is a fragmentary sectional view along line 18-18 of FIG.17;

[0117]FIG. 19 is an enlarged, fragmentary elevation sectional view of aportion of FIG. 13;

[0118]FIG. 20 is an alternate view along line 13-13 of FIG. 11;

[0119]FIG. 21 is a sectional view along line 21-21 of FIG. 20;

[0120]FIG. 22 is an enlarged fragmentary view of a portion of FIG. 21;

[0121]FIG. 23 is an alternate embodiment of a fry wheel in accordancewith the present invention;

[0122]FIG. 24 is another alternate embodiment fry wheel in accordancewith the present invention;

[0123]FIG. 25 is a front perspective view of a packaging device inaccordance with the invention;

[0124]FIG. 26 is a rear perspective view of the device of FIG. 25;

[0125]FIG. 27 is a top plan view of the device of FIG. 25;

[0126]FIG. 28 is a side elevation view, partially in section andpartially broken away of the packaging device of FIG. 25;

[0127]FIG. 29 is a front elevation view of the device of FIG. 25;

[0128]FIG. 30 is a front perspective view of a portion of an automatedcontainer handling system in accordance with the invention;

[0129]FIG. 31 is a top plan view of the container handling system ofFIG. 30;

[0130]FIG. 32 is a side elevation view, partially broken away of theautomated container handling system of FIG. 30;

[0131]FIG. 33 is a rear elevation view of the container handling systemof FIG. 30;

[0132]FIG. 34 is a front perspective view of the container handlingsystem of FIG. 30 shown in another operative position;

[0133]FIG. 35 is a top plan view of the container handling system ofFIG. 34;

[0134]FIG. 36 is a side elevation view, partially broken away of thecontainer handling system of FIG. 34;

[0135]FIG. 37 is a rear elevation view of the container handling systemof FIG. 34;

[0136]FIG. 38 is a front elevation view of a portion of a containerhandling apparatus in accordance with the invention;

[0137]FIG. 39 is a front elevation view of another portion of thecontainer handling apparatus of FIG. 34;

[0138] FIGS. 40-42 illustrate a front diagrammatic elevation viewillustrating a portion of the container handling apparatus in accordancewith the invention;

[0139] FIGS. 43-44 illustrate a side elevation view, partly in section,of a portion of the food packaging apparatus in accordance with theinvention;

[0140]FIG. 45 is a top plan view of a food packaging device inaccordance with the present invention;

[0141]FIG. 46 is a perspective view of a container-receiving receptaclein accordance with the present invention;

[0142]FIG. 47 is a top plan view of the device of FIG. 47;

[0143]FIG. 48 is a sectional view along line 48-48 of FIG. 47;

[0144]FIG. 49 is a cross-sectional view along line 49-49 of FIG. 47 andfurther including a portion of a conveyor system in accordance with thepresent invention;

[0145]FIG. 50 is a sectional view along line 50-50 of FIG. 49;

[0146]FIG. 51 is a front elevation view of a carton useful in accordancewith the present invention;

[0147]FIG. 52 is a rear elevation view of a carton useful in accordancewith the present invention;

[0148]FIG. 53 is a sectional view along line 53-53 of FIG. 52;

[0149]FIG. 54 is a bottom plan view of the container of FIG. 51;

[0150]FIG. 55 is a sectional view along line 55-55 of FIG. 57;

[0151]FIG. 56 is a perspective view showing use of the food container ofFIG. 51;

[0152]FIG. 57 is a perspective view of a food container useful inaccordance with the present invention;

[0153]FIG. 58 is an alternate embodiment perspective view of a containeruseful in accordance with the invention;

[0154]FIG. 59 is a development view of the carton of FIG. 51;

[0155]FIG. 60 is a side elevation view of the carton of FIG. 51;

[0156]FIG. 61 is a sectional view of a portion of the food packagingdevice of FIG. 25;

[0157]FIG. 62 is a sectional view of a portion of a food storage devicein accordance with the present invention;

[0158]FIG. 63 is a sectional view of the food storage device of FIG. 62;

[0159]FIG. 64 is a side elevation view, partly in section, a hood systemin accordance with the present invention;

[0160]FIG. 65 is a perspective view of an automated seasoning device inaccordance with one aspect of the invention;

[0161]FIG. 66 is a side elevation view of the seasoning device of FIG.65;

[0162]FIG. 67 is a front elevation view of the seasoning device of FIG.65;

[0163]FIG. 68 is a top plan view of the seasoning device of FIG. 65;

[0164]FIG. 69 is a diagrammatic view of a control system in accordancewith the present invention;

[0165]FIG. 70 is a diagrammatic view of a control system in accordancewith the present invention;

[0166]FIG. 71 is a diagrammatic view of a frying cycle in accordancewith the present invention;

[0167]FIG. 72 is a schematic illustration of a sample touch screenmonitor useful in accordance with the invention;

[0168]FIG. 73 depicts another touch screen layout in accordance with thepresent invention;

[0169]FIG. 74 is a perspective view of another automated food processingsystem in accordance with the invention;

[0170]FIG. 75 is a perspective view of another embodiment of a foodprocessing system in accordance with the present invention;

[0171]FIG. 76 is a schematic view, partly in section, of the foodprocessing system of FIG. 74;

[0172]FIG. 77 is a side elevation view of a portion of a bulk dispensingdevice in accordance with the present invention, partly in section;

[0173]FIGS. 77A and 77B are perspective views of an alternativeembodiment of a bulk dispensing device in accordance with the presentinvention;

[0174]FIGS. 77C and 77D are perspective and side elevation fragmentaryviews, partly in section, of an alternate food dispensing device inaccordance with the present invention;

[0175]FIG. 78 is a side perspective view of a portion of a bulkdispensing device in accordance with the present invention, partly insection;

[0176]FIG. 79 is a partial fragmentary perspective view of a conveyorbody in accordance with the present invention;

[0177]FIG. 80 is a top plan view of the conveyor body of FIG. 79;

[0178]FIG. 81 is a perspective view of a portion of the food dispensingdevice of FIG. 74;

[0179]FIG. 82 is a fragmentary perspective view of a portion of the doorassembly illustrated in FIG. 81;

[0180]FIG. 83 is a fragmentary perspective view of a portion of oneembodiment of a food dispensing device in accordance with the presentinvention, partly in section;

[0181]FIG. 84 is a fragmentary perspective view of a portion of anotherembodiment of a food dispensing device in accordance with the presentinvention, partly in section;

[0182]FIG. 85 is a fragmentary perspective view, partly in section, of afry module in accordance with one embodiment of the present invention;

[0183]FIG. 86 is a fragmentary perspective view illustrating a portionof a packaging module in accordance with the present invention;

[0184]FIG. 87 is a front elevation view of various portions of a foodpackaging device in accordance with the present invention;

[0185]FIG. 88 is a fragmentary perspective view of various portions of apackaging device in accordance with the present invention;

[0186]FIG. 89A is a fragmentary side elevation view, partly in section,illustrating various stages of operation of one embodiment of a cartonerection device in accordance with one embodiment of the invention;

[0187]FIG. 89B is a fragmentary elevation view, partly in section, ofthe device shown in FIG. 89A illustrating various stages of erecting acarton in accordance with the present invention;

[0188]FIG. 89C is a fragmentary perspective view of portions of oneembodiment of a container handling apparatus in accordance with thepresent invention;

[0189]FIG. 89D is a fragmentary perspective view illustrating a portionof the operation of the automated packaging device in accordance withone embodiment of the present invention;

[0190]FIG. 89E is a fragmentary perspective view illustrating part ofthe operation of the packaging device in accordance with one embodimentof the present invention;

[0191]FIG. 89F illustrates a side elevation sectional view of variousoperations of a portion of the packaging device in accordance with oneembodiment of the present invention;

[0192]FIGS. 89G and 89H are fragmentary side elevation views showing aportion of the operation of one embodiment of a packaging device inaccordance with the present invention;

[0193]FIG. 891 is a fragmentary perspective view of a portion of apackaging device in accordance with one embodiment of the inventionillustrating a portion of the operation of that device;

[0194]FIG. 90A is a fragmentary perspective view of one embodiment of amechanical arm assembly for the packaging device in accordance with thepresent invention;

[0195]FIG. 90B is a fragmentary perspective view showing portions of themechanical arm and elevator assembly of a packaging device in accordancewith the present invention;

[0196]FIG. 90C is a fragmentary perspective view illustrating a portionof the embodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof;

[0197]FIG. 90D is a fragmentary perspective view illustrating a portionof the embodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof;

[0198]FIG. 90E is a fragmentary perspective view illustrating a portionof the embodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof;

[0199]FIG. 90F is a fragmentary perspective view illustrating a portionof the embodiment of FIGS. 74 and 87-90A illustrating a portion of theoperation thereof; and

[0200]FIG. 91 illustrates a fragmentary perspective sectional view of apackaging device in accordance with the present invention illustratingan alternate embodiment of a filled French fry container holding devicein accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION General

[0201] In accordance with the present invention, an automated foodprocessing system and method is provided. The automated food processingsystem and method in accordance with the invention allows food to bedispensed, fried and packaged in a suitable container or alternativelydispensed to a food holding area for subsequent processing by a humanoperator.

[0202] Referring to the Figures generally, where like reference numeralsrefer to like elements, and in particular to FIGS. 1 and 3 and 74 and76, there is illustrated an automated food processing system 100 inaccordance with the invention and an automated food processing system1100 in accordance with the invention. Automated food processing systems100 and 1100 include a food dispensing device 200, 1200, a fry device400, 1400 and a food packaging device 600,1600, respectively. Inaccordance with one embodiment of the present invention, each ofdispensing, fry and packaging devices 200, 400 and 600, and 1200,1400and 1600, respectively, can be constructed and are sometimes illustratedin “modular” construction or form. By “modular” construction or form itis meant that dispensing, fry and packaging devices 200, 400 and 600,and 1200, 1400 and 1600, respectively, can exist and be contained inseparate cabinets, for example, and also operate independently of theother devices. Thus, if one of dispensing, fry and packaging devices200, 400 and 600, or 1200, 1400 and 1600, respectively, are inoperativeor are otherwise deactivated, the function of the deactivated orinoperative device can be performed manually. For example, food to befried could be manually dispensed in place of dispensing device 200 or1200. Alternatively, food to be fried could be fried in a conventionalfry vat after being dispensed from dispensing device 200 or 1200 inplace of using fry device 400 or 1400 and food that is dispensed andfried in dispensing and fry devices 200 and 400, respectively, could, inturn, be packaged manually, for example.

[0203] To facilitate such modular construction and use, each ofdispensing, fry and packaging devices 200, 400 and 600, and 1200, 1400and 1600, respectively, can be contained in a separate wheeled cabinet,202, 402 and 602, and 1202,1402 and 1602, respectively, as illustratedin FIGS. 1 and 74. Alternatively, dispensing, fry and packaging devices200, 400 and 600, and 1200, 1400 and 1600, respectively, could bemounted as a single unit or in a single cabinet or in “non-modularform,” as desired, or more than one of such devices 200, 400 and 600 or1200, 1400 and 1600, could be so mounted or combined.

[0204] A suitable control system for the dispensing, fry and packagingdevices is also provided. As will be described more completelyhereafter, in one embodiment, the control system includes a centralcontrol system 110 or 1110 that can interface with a point-of-salesystem 112 or 1112, respectively. The central control system willcommunicate with separate subcontrol systems 114, 116 and 118 or 1114,1116 and 1118, respectively, one for each of the dispensing, fry andpackaging devices 200, 400 and 600 and 1200, 1400 and 1600,respectively. Alternatively, a single central control system (not shown)could be utilized in place of individual control systems for each ofdevices 200, 400 and 600 or devices 1200, 1400 and 1600. Similarly, asanother alternative, a single central control system could be utilizedto control the overall operation of automated food processing system 100or 1100 as well as controlling the individual functions and aspects ofdispensing, fry and packaging devices 200, 400 and 600 or 1200, 1400 and1600, respectively.

[0205] The basic operations of dispensing devices 200 and 1200, frydevices 400 and 1400 and food packaging devices 600 and 1600 will now bebriefly discussed and discussed in detail hereafter.

[0206] Briefly, dispensing devices 200 and 1200 each function todispense a quantity of food to be fried to fry device 400 or 1400. Inone aspect of the invention, any suitable food dispensing device can beutilized. Dispensing devices 200 and 1200 can include a cabinet 202 or1202, respectively, to house the components of dispensing device 200 or1200. In one embodiment, cabinet 202 or 1202 will be refrigerated,preferably below 32° F. so that the food contents therein will remainfrozen. This allows the food stored in dispensing devices 200 or 1200 toremain therein for a long period of time, much longer than if thecontents were merely refrigerated (above freezing) or merely at roomtemperature.

[0207] In the illustrated embodiments, dispensing devices 200 and 1200include an uncooked bulk food dispensing container 204 and 1204,respectively. Uncooked bulk food dispensing containers 204 and 1204 maybe utilized for food such as French fries or chicken nuggets, forexample. Other types of food may also be contained in a dispenser suchas uncooked bulk food dispensing containers 204 and 1204. Typically,those types of food would be in the form of relatively small piecescompared to relatively large food pieces such as chicken patties, forexample.

[0208] For relatively large food pieces, a large food dispensingcontainer is utilized. In one embodiment, the large food dispensingcontainer is in the form of magazine food dispensers 206 and 1206.

[0209] Food dispensed from a dispenser of dispensing devices 200 and1200 is deposited on a conveyor 208 or 1208, respectively, that, inturn, directs the deposited food to a secondary or dump container 210 orbottomless container 1210 for subsequent discharge from dispensingdevice 200 or 1200, respectively.

[0210] In the illustrated embodiments, uncooked bulk food dispensingcontainers 204 and 1204, magazine food dispensers 206 and 1206,conveyors 208 and 1208 and secondary containers 210 and 1210 arecontained in cabinet 202 or 1202, respectively, which is a refrigeratedenvironment, preferably maintained below freezing (32° F. or lower).

[0211] While any suitable conveyor can be utilized in one aspect,conveyors 208 and 1208 are each preferably a vibratory conveyor,vibrated by a suitable vibratory mechanism that vibrates conveyor bodies214 and 1214, respectively. Conveyor bodies 214 and 1214 may each takethe form of a suitably shaped tray, for example.

[0212] By containing the foregoing components in a refrigerated andpreferably frozen environment, consistency in food preparation anddispensing is achieved, thereby contributing to the overall efficient,effective and uniform performance of automated food processing systems100 and 1100.

[0213] Secondary containers 210 and 1210 can be of a form as desired andincludes suitable weighing mechanisms 216 and 1216, respectively, topermit a determination of the quantity of food contained in secondarycontainers 210 and 1210. Weighing mechanisms 216 and 1216 can each beany suitable device to weigh the contents or otherwise determine theamount of food in secondary container 210 or 1210. Weighing mechanisms216 and 1216 may comprise a load cell or a mechanism for determining thevolume of food deposited into the respective one of secondary containers210 and 1210, for example. In this manner, the amount of food that ischarged to one of fry devices 400 and 1400 at a particular time can bedetermined. In addition, weighing mechanisms 216 and 1216 can beoperated during operation of conveyors 208 and 1208, respectively, andthe operation of conveyors 208 and 1208 continued until a desired amountof food is deposited in secondary container 210 or 1210. In this manner,a precise amount of food can be delivered to a respective one ofsecondary containers 210 and 1210, thereby permitting consistency anduniformity in the portion of food that is delivered to fry device 400 or1400. This is also important to ensure that a sufficient quantity offood is being cooked by automated food processing systems 100 and 1100.

[0214] Prior to activation of dumping mechanisms 218 or 1218, dischargedoors 220 or 1220 of cabinets 202 and 1202, respectively, are opened byoperation of a door opening device which can be any suitable device asdesired and in one illustrated embodiment is a cylinder 222 attached todischarge door 220 and movable up and down in the direction of arrow B.A respective one of discharge doors 1220 of dispensing device 1200 isopened by lateral movement of the associated one of secondary container1210, as illustrated in, for example, FIG. 76. Cabinets 202 and 1202 arepreferably insulated with a suitable insulating material 224 and 1224that are also provided in discharge doors 220 and 1220. The provision ofa suitable insulating material is important, particularly sincedispensing devices 200 and 1200 will typically be located proximate oradjacent one of fry devices 400 and 1400 that operate at a substantiallyelevated temperature, thereby typically generating substantial heat.

[0215] In the illustrated embodiments, dispensing devices 200 and 1200each includes four dispensing lanes from which food is discharged fromdispensing devices 200 and 1200, respectively, and to a suitablelocation such as one of fry devices 400 and 1400. After dispensingthrough discharge door 220, cylinder 222 is activated to close dischargedoor 220. Similarly, dumping mechanism 218 of secondary container 210 isactivated to return secondary container 210 to its upright position toreceive more food.

[0216] For dispensing device 1200, after dispensing through one of doors1220, as the respective one of secondary containers 1210 is retracted,the associated one of doors 1220 closes by gravity, without the need fora separate closing mechanism.

[0217] Each of fry devices 400 and 1400 includes, respectively, a frywheel 404, a fry vat 406 for containing and heating a suitable cookingoil and a drive mechanism 408 for suitably rotating fry wheel 404. It isto be understood that in accordance with one aspect of the invention anysuitable frying device can be utilized.

[0218] In the illustrated embodiment of FIGS. 3, 11-16 and 74, frydevices 400 and 1400 include a plurality of, in this case four, separatefry wheels 404, 410, 412 and 414, as well as four separate fry vats 416,406, 420 and 418 and a separate drive mechanism 408 for each fry wheel,each dedicated to a particular one of fry wheels 404, 410, 412 and 414.

[0219] In various embodiments, a separate drive mechanism is providedfor each of fry wheels 404, 410, 412 and 414 and can be suitably locatedin cabinet 402 or 1402, preferably in a location that is above the levelof cooking oil present in the associated one of fry vats 416, 406, 420and 418, respectively. Fry module 1400 is similar to fry module 400,except that fry module 1400 includes a foam deck and overflowarrangement as hereafter described.

[0220] The suitable rotation of each of fry wheels 404, 410, 412 and 414can be as desired to direct food articles loaded therein down andthrough the fry vat until reaching the other side of the fry vatwhereupon the food articles are discharged. The rotation can be eithercontinuous or a periodic incremental rotation. For example, a suitabledrive mechanism can be provided to periodically rotate fry wheel 410 ina desired rotational increment, which may be based on the number ofcompartments contained in fry wheel 410. In the illustrated embodimentsof FIG. 13, for example, fry wheel 410 comprises eight food compartments422, 424, 426, 428, 430, 432, 434, and 436. Each of food compartments422-436 is a perimeter food compartment and open to the perimeter orexterior of fry wheel 410. Each of fry wheels 404, 412 and 414 can besimilarly configured.

[0221] As described in more detail hereafter, each of compartments422-436 is formed from a perforated curved compartment forming member510.

[0222] In the rotation of fry wheel 410, a periodic incremental rotationcan be based upon 360° divided by the number of compartments. Thus, forexample, in the illustrated embodiments of FIG. 13 and FIG. 76, eachperiodic rotation would consist of a rotation of 360° divided by eightcompartments or a periodic rotation increment of 45°. Thus, asillustrated in FIG. 13, the food contained, in this case French fries,in compartments 424-430 would remain in cooking oil 454 contained in fryvat 406 for all or part of four incremental rotations, after which thefood would be discharged from fry wheel 410 in the next incrementalrotation thereof. For example, as illustrated in FIG. 13, compartment422 is ready to receive a charge of food to be fried, compartment 424has a charge of food that has been just immersed in cooking oil 454.Cooking oil 454 is at a level H as illustrated in FIG. 13, which isdependent upon the amount of food contained in compartments 422-436 thatare submerged in cooking oil 454.

[0223] Similarly, compartment 426 has food contained therein that hasgone through two incremental 45° rotations of fry wheel 410, compartment428 has food contained therein that has undergone three incrementalrotations and food compartment 430 has food contained therein that hasundergone four incremental rotations of fry wheel 410 and compartment432, which is now empty, has discharged the food contained therein uponthe last incremental rotation of fry wheel 410. Thus, upon the nextincremental rotation of fry wheel 410, which is in the clockwisedirection as shown by arrow B of FIG. 13, the food contained in foodcompartment 430, which in this case is a quantity of French fries 455,will be discharged from compartment 430 to the food packaging devicewhich is hereafter briefly described.

[0224] Upon discharge of food, which in this case is a quantity ofFrench fries from one of compartments 422-436 of a fry wheel, such asfry wheel 410 as illustrated in FIGS. 3 and 76, the food is depositedonto a respective one of inlet chutes 604 or 1604 of food packagingdevices 600 and 1600.

[0225] For packaging module or device 600, from inlet chute 604, thefood from inlet chute 604 and previously received from fry wheel 410 isdeposited into dispensing member 606. Typically, dispensing member 606will be compartmented into a plurality of compartments that are arrayedalong the periphery of rotatable food dispensing member 606.

[0226] Rotatable food dispensing member 606 has a discharge location todischarge the food deposited therein. The discharge location isgenerally located towards an upper portion of rotatable food dispensingmember 606. A food dispensing chute mechanism 608 is positioned toreceive cooked food from the discharge location of rotatable fooddispensing member 606. In a preferred embodiment, food dispensing chutemechanism 608 incorporates a device for weighing or otherwisedetermining the quantity of food that has been deposited into fooddispensing chute mechanism 608. This ensures that when food is dispensedfrom food dispensing chute mechanism 608 a minimum quantity of food willbe dispensed, thereby ensuring that a container 611 or other packagethat is to receive the food from mechanism 608 will receive a desiredcharge.

[0227] Food packaging device 600 preferably also includes a suitableautomated container handling system 610. Automated container handlingsystem 610 is capable of, in a preferred embodiment, selecting container611 of a desired size, retrieving and grasping container 611, erectingunerected container 611 into an erected form and holding the erectedcontainer 611 in position to receive food dispensed from food dispensingchute mechanism 608.

[0228] After food container 611 receives food from food dispensing chutemechanism 608, automated container handling system 610 is capable ofmoving container 611 having food deposited therein to a containerreceiving receptacle 612 which receptacle 612 can be transported via aconveyor system 614 to a desired location for subsequent pickup ofcontainer 611 having food contained therein by a human operator, forexample.

[0229] Preferably, a food overflow collection member is provided tocollect any food dispensed by food dispensing chute mechanism 608 thatis not deposited into container 611. In one embodiment, the overflowfood collection device is a rotatable food collection member 613.Overflow food collection member 613 functions to collect food dispensedby food dispensing chute mechanism 608 that is not received in container611 and to recycle food collected by overflow food collection member 613into food dispensing chute mechanism 608 for subsequent dispensing to acontainer in a first-in, first-out manner so that overflow food ispromptly recycled to dispensing chute 608 for dispensing to a container.

[0230] Preferably, food packaging device 600 is configured to include aprovision by which food contained in dispensing device 600 is routed towaste where it is not desired to dispense such food into a foodcontainer. Such a condition could arise, for example, if food is heldfor too long a period in food packaging device 600. This function may beaccomplished, for example, by providing a waste discharge location whichcan be in the form of a waste chute 615 to which food from rotatablefood dispensing member 606 and overflow food collection member 613 canbe directed. In one embodiment, chute mechanism 608 is lowered andmember 606 is rotated to dispense food to chute mechanism 608, which inturn dispenses into member 613. Member 613 is rotated counterclockwiseto deliver food to waste chute 615. This process can be continued untilall of the food in device 600 is so emptied, if desired.

[0231] Preferably, a suitable structure for applying a desired quantityof seasoning to food contained in food packaging device 600 is provided.In the embodiment illustrated in FIG. 3, a food seasoning device 616 isprovided. Food seasoning device 616 can be any suitable seasoning deviceas desired. In one embodiment, food seasoning device 616 dispenses adesired quantity of seasoning from a bulk storage container through adelivery tube and onto food located in rotatable food dispensing member606.

[0232] Preferably, and in the embodiment illustrated in FIG. 3, a foodseasoning device 616 is provided that directs a desired quantity ofseasoning onto food that is contained in a bottom portion of rotatablefood dispensing member 606 and inlet chute 604 via a seasoningdispensing head 618.

[0233] Preferably, conveyor system 614 is composed of a raceway 620 thatis an endless loop around the periphery of the top surface of cabinet602 of food packaging device 600, which in one embodiment can be amodular, wheeled cabinet. Conveyor system 614 causes container receivingreceptacle 612 to travel around raceway 620 to a food container pickuplocation 622 where a human operator can pickup food containers havingfood therein. Preferably, conveyor system 614 includes structure forstopping movement of a container/receiving receptacle 612 at apredetermined location when carrying a food container, such as at foodcontainer pickup location 622. Such structure in one embodiment maycomprise a gate structure 928 or 928′ of FIG. 45 and FIGS. 25-27,respectively, that extends across at least a portion of raceway 620 inthe vicinity of the predetermined location. Any suitable type of barrierstructure can be utilized to prevent the desired movement. Mostpreferably, gate structure 928 or 928′ will be located at a height thatis above the top of the receptacle when located on conveyor system 614so that movement of container/receiving receptacle 612 is prevented orstopped only for a receptacle 612 that has a food container 611 disposedthereon. Note that the pickup location can be configured as desired andslightly different configurations 622 and 622′ are shown in FIG. 45 andFIGS. 25-27, respectively.

[0234] The basic elements of food packaging device 1600 may include aninlet chute 1604, preferably a salting device 1606, preferably gates1608 and 1610 operatively associated with inlet chute 1604, a holdingbin 1612 for French fries, an automated French fry container fillingdevice 1614 that includes an automated mechanical arm 1616 and acarriage 1618, a filled French fry container drop-off location andholding structure 1620 and preferably, a container handling system 1622typically for carton storage, carton erection and handling, suitable foruse with French fry container filling device 1614, as hereafterdescribed in further detail. As shown in FIG. 74, an inlet chute 1603 isprovided to feed cooked food products into holding bin 1603′ receivedfrom fry wheel 404, typically for food items such as chicken filets,fish filets or chicken nuggets, for example, received from lane 1240.Bin 1602′ may be heated, if desired.

[0235] Briefly, the operation of packaging device or module 1600 is asfollows.

[0236] Food from fry module 400 or 1400, such as from fry wheel 410 isdeposited onto the inlet portion of inlet chute 1604. Typically, gate1608 will be positioned to prevent the passage of French fries past gate1608. Salting device 1606 then operates to apply a desired quantity ofsalt or other seasoning to the bulk amount of French fries on inletchute 1604 contained upstream of gate 1608. Salting device 1606 can belaterally moved along a carriage 1606′ during dispersing of the salt orother seasoning to help ensure seasoning coverage over the entirequantity of French fries in inlet chute 1604 that are upstream of gate1608. Alternatively, one or more salter devices 1606 can be mounted in adesirable stationary position above inlet chute 1604 or some otherdesirable location without a carriage. Salter device 1606 is similar tofood seasoning device 616 described in detail hereafter.

[0237] Gate 1608 preferably is composed of reciprocable fingers that canbe raised and lowered relatively rapidly so that as the bulk amount ofFrench fries travel past gate 1608, the fingers provide a declumpingaction on the French fries. Gate 1610 can be in a position to retain theFrench fries at a lower portion of inlet chute 1604, such as ifadditional French fries are not needed in holding bin 1612. When gate1610 is in an open or lowered position, French fries in the low portionof chute 1604 are free to travel into holding bin 1612.

[0238] A vibratory mechanism 1624 as shown in FIG. 76 may also beassociated with inlet chute 1604 so that inlet chute 1604 vibrates tofacilitate the passage of fries along inlet chute 1604 and into holdingbin 1612.

[0239] French fry container filling device 1614 operates to fill erectedFrench fry containers that typically will be individual portion-sizedFrench fry containers, and is composed of a multilink mechanical arm1616. Mechanical arm 1616 has an end-of-arm tool 1626 that is capable ofgrasping a French fry container, scooping it into French fries containedin holding bin 1612 to fill the French fry container with French fries,relatively gently shaking the filled French fry container to seat theFrench fries in the container and to dislodge any loosely containedFrench fries and depositing the filled French fry container at adrop-off location. Preferably, the filled French fry container is shakenover the holding bin so that French fries that are shaken from thecontainer fall into holding bin 1612 and so that French fries becomemore firmly seated in the French fry container.

[0240] In one embodiment, automated mechanical arm 1616 can beconfigured and operated to mimic the arm, wrist and hand action of ahuman operator in scooping French fries into a French fry container tofill the container and shaking the filled French fry container to removeloosely contained French fries and to more firmly seat French friescontained in the container.

[0241] Food packaging device 1600 preferably also includes a suitablecontainer handling system 1622. Container handling system 1622 iscapable of, in a preferred embodiment, selecting a container 611 of adesired size, retrieving and grasping container 611, erecting unerectedcontainer 611 into an erected form and delivering erected container 611to French fry container filling device 1614.

[0242] Referring to FIGS. 2 and 75, there are illustrated variousalternate embodiments of automated food processing systems 101 and 1101in accordance with the invention. Automated food processing systems 101and 1101 include, respectively, a food dispensing device 201, 1201 whichis similar to food dispensing devices 200 and 1200, previously brieflydescribed, where like reference numerals represent like elements. Fooddispensing devices 201 and 1201 include fewer uncooked bulk fooddispensing containers 204,1204 and additional magazine food dispensersthat are similar to magazine food dispensers 206 and 1206, previouslyreferred to. Otherwise, dispensing devices 201 and 1201 are similar todispensing devices 200 and 1200, previously described, respectively.

[0243] Automated food processing systems 101 and 1101 also include frydevices 400 and 1400, respectively, which have been described.

[0244] One primary distinction between automated food processing systems100 and 1100 and automated food processing systems 101 and 1101 is thatautomated food processing systems 101 and 1101 do not include anautomated packaging device such as automated packaging devices 600 or1600. In place of food packaging devices 600 or 1600, a food storagedevice 635 is provided, which may be contained on a movable cart 635′.Food storage device 635 allows food cooked by food frying devices 400 or1400 to be stored in a heated environment for subsequent manualprocessing. As configured in FIGS. 2 and 75, food storage device 635includes separate heated product receiving receptacles 637, 639, 641 and643. Each receptacle 637, 639, 641 and 643 is dedicated to receivingfood from a respective one of fry wheels 410, 412, 414 and 404,respectively. In addition, each receptacle 637-643 can have placedtherein a suitable container to receive food, such as handled trays 645,647, 649 and 651.

[0245] As illustrated in FIG. 2, a food item F is being discharged fromfry wheel 414 down a chute 653 and into handled tray 649 containedwithin heated receptacle 641. Food item F can be stored therein for aperiod of time until it is ready for subsequent processing.

[0246] It is to be understood that other devices or modules can be usedin place of any of food dispensing device 200, fry device 400 and foodpackaging device 600. For example, referring to FIGS. 74-91, there areillustrated alternate embodiments, namely, dispensing device or module1200, fry device or module 1400 and packaging device or module 1600.

Food Dispensing Device

[0247] Referring to the Figures generally and in particular to FIGS.1-10 and 74-84, there are illustrated various embodiments of fooddispensing devices and portions thereof in accordance with theinvention.

[0248] In two embodiments, food dispensing devices 200 and 1200 areillustrated or partially illustrated in each of FIGS. 1 and 3-8 and 74and 76-84. Food dispensing device 200 includes a cabinet 202, bulkuncooked food dispensing containers 204, 205 and 207, magazine fooddispensers 206, 209, 211 and 213, and a suitable conveyor system foreach lane 234, 236, 238 and 240 of food dispensing device 200.Similarly, food dispensing device 1200 includes a cabinet 1202, bulkuncooked food dispensing containers 1204, 1205 and 1207, magazine fooddispenser 1206, 1209, 1211, 1213 and 1215, and a suitable conveyorsystem for each lane 1234, 1236, 1238 and 1240 of food dispensing device1200. Any suitable number of magazine dispensers can be used for aparticular lane, such as one, two, three, four, five or more, and theillustrated embodiment of five is merely an example. As configured inFIGS. 1 and 74, for example, lanes 234, 1234 receive material from bulkhoppers 204,1204, lanes 236, 1236 receive food material from bulkhoppers 205, 1205, lanes 238, 1238 receive food material from bulkhoppers 207, 1207 and lanes 240, 1240 receive dispensed food frommagazine food dispensers 206, 209, 211 and 213, and 1206, 1209, 1211,1213 and 1215, respectively, as will be described hereinafter in greaterdetail, particularly with respect to food dispensing device 201 of FIG.2, for example. Food dispensing device 1200 is similar to fooddispensing device 200, except that device 1200 has a different secondarycontainer, exterior doors and differences in the conveyor apparatus, ashereafter described.

[0249] Each lane 234, 236, 238 and 240 or 1234, 1236, 1238 and 1240dispenses food that is subsequently directed to fry wheels 410, 412, 414and 404, respectively.

[0250] The components of lane 238 will now be described in detail and itis to be understood that the components of lanes 234 and 236 aresimilar. Lane 238 includes uncooked bulk food dispensing container 207and a food handling system 242 which in this embodiment is identical foreach lane 234, 236, 238 and 240 as well as for each lane of fooddispensing device 201. It should be noted that food handling system 242,as for example, illustrated in FIGS. 3-6 is depicted with respect tolane 240 and that food handling system 242 is the same for each lane234, 236, 238 and 240.

[0251] Food handling system 242 includes conveyor system 208, secondarycontainer 210, weighing mechanism 216 and dumping mechanism 218.Conveyor system 208 includes vibratory mechanism 212 and conveyor body214.

[0252] Uncooked bulk food dispensing container 204 can be of a shape anddimension generally as desired. Preferably, uncooked bulk fooddispensing container 204 has an upper opening to permit a supply of foodto be placed in uncooked bulk food dispensing container 204. Upperopening 244 as illustrated is located in an upper rear portion ofuncooked bulk food dispensing container 204 and can be convenientlyaccessed via a rear door 246 of cabinet 202. Rear door 246 preferably isinsulated with suitable insulation material 224.

[0253] Uncooked bulk food dispensing container 204 is composed of a pairof opposed upper sidewalls 248, a pair of generally opposed lowersidewalls 250 and front and rear walls 252 and 254, respectively, whichconnect together upper sidewalls 248 and lower sidewalls 250 to provideuncooked bulk food dispensing container 204. Front wall 252 includes alower portion 252′ that extends inwardly from top to bottom to furtherfacilitate discharge of food contained in uncooked bulk food dispensingcontainer 204. Preferably, lower generally opposed sidewalls 250 areslightly indented from top to bottom to facilitate the discharge of foodthat may be contained therein.

[0254] Uncooked bulk food dispensing container 204 includes a bottomopening 256 that permits the discharge of food contained therein. Bottomopening 256 can be configured as desired and in the illustratedembodiment the entire bottom of uncooked bulk food dispensing container204 is open. In the illustrated embodiment, uncooked bulk fooddispensing container 204 is particularly suited for use with food suchas French fries and chicken nuggets as well as other types of food ofrelatively small size.

[0255] Uncooked bulk food dispensing container 204 is suitably mountedwithin cabinet 202. While a suitable mounting structure can be utilized,it is preferred to utilize a structure that will minimize heat transferfrom the exterior and through cabinet 202 to uncooked bulk fooddispensing container 204, particularly where cabinet 202 isrefrigerated, especially where temperatures below freezing are utilized.In that regard, front mounting bracket 258 and rear mounting bracket 260each are configured to minimize heat transfer from cabinet 202 touncooked bulk food dispensing container 204. In that regard, frontmounting bracket 258 and rear mounting bracket 260 include openings,258′ and 260′, respectively, to minimize such heat transfer and tomaximize airflow around the containers 204, 205, 207 and dispensers 206,209, 211 and 213. Similarly, materials of low thermal conductivity canalso be utilized, if desired, for brackets 258 and 260. Generally, tominimize heat transfer and to maximize airflow, the surface area contactand cross-sectional area of mounting brackets 258 and 260 should beminimized to reduce heat transfer and “hot spots” on uncooked bulk fooddispensing container 204.

[0256] As illustrated in FIGS. 3 and 4, for example, food contained inuncooked bulk food dispensing container 204 passes through bottomopening 256 and onto conveyor body 214 which in the illustratedembodiment is a suitably dimensioned pan. Conveyor body 214 is suitablymounted to vibratory mechanism 212 to effect vibration of conveyor body214 as well as food contained therein and food contained in uncookedbulk food dispensing container 204, and in particular the lower portionof container 204. This vibration facilitates the discharge of food fromuncooked bulk food dispensing container 204 and causes food contained inconveyor body 214 to travel in the direction of arrow G. Any suitableconveyor system can be used in accordance with one aspect of theinvention.

[0257] A preferred type of vibratory mechanism is available from FMCTechnologies, Inc. of Chicago, Ill. marketed under the model F-010-B andDF-010-B. Vibratory mechanism 212 is preferably an electromagneticvibrating mechanism. Vibratory mechanism 212 in one embodiment producesa vibrating stroke at the surface of conveyor body 214. The strokeresults from the action of an electromagnet that pulls conveyor body 214sharply down and backward and then allows it to spring up and forward.Typical vibratory mechanisms of this type run at about 3,600vibrations/minute at 60 Hz power. The power of the vibrating stroke canbe controlled by a suitable drive module as is known in the art. In oneembodiment, vibratory mechanism 212 can be operated at about 85% of fullpower during filling of secondary container 210 with food. For the firstpart of a fill cycle of secondary container 210, vibratory mechanism 212can be run continuously, then pulsed by turning its power on and offperiodically so that vibratory mechanism 212 operates about 50% of thetime to finish filling secondary container 210 with a desired quantityof food, thereby providing better control on the last part of the foodcharged to secondary container 210.

[0258] Food dispensing device 200 preferably includes a suitablemechanism to determine the weight or volume of a charge of fooddelivered by conveyor 208 to secondary container 210. The amount may bedetermined either by weight or volume, for example. In the illustratedembodiment, weighing mechanism 216 is operatively interfaced withsecondary container 210 to provide an indication of the weight of foodcontained in secondary container 210. The weight sensed in secondarycontainer 210 by weighing mechanism 216 is communicated with subcontrolsystem 114 of food dispensing device 200. Subcontrol system 114 monitorsand controls the operative functions of food dispensing device 200 ashereinafter described in greater detail.

[0259] Optionally, a level sensor can be employed in uncooked bulk fooddispensing container 204 to provide an indication of the amount of foodstored therein that is available for dispensing. Any suitable levelindicator known in the art can be utilized in accordance with theinvention such as photoelectric, weight, turning fork and others, forexample.

[0260] Secondary container 210 can be considered as a dump container andhas associated therewith, dumping mechanism 218 for rotating secondarycontainer 210 through an arc as indicated by arrow B sufficiently todump the contents of secondary container 210. Any suitable dumpingmechanism can be utilized.

[0261] Illustrated dumping mechanism 218 includes a dump cylinder 264that is secured to a base 266. Dump cylinder 264 can selectively rotatea drive gear or wheel 268 that, in turn, is operatively associated witha follower gear or wheel 270 to cause rotation of follower gear or wheel270. Secondary container 210 is rigidly secured to follower gear orwheel 270 so that when follower gear or wheel 270 is rotated by drivegear or wheel 268 secondary container 210 is rotated through an arc thatcauses secondary container 210 to rotate forward to a dumping positionas illustrated in phantom lines in FIG. 3 indicated by reference numeral210′. Such movement is caused by extension of dump cylinder 264.Similarly, retraction of dump cylinder 264 moves secondary container 210from the dump position indicated by reference numeral 210′ to theupright position indicated by reference numeral 210 in FIG. 3 wheresecondary container 210 is ready to receive a charge of food fromconveyor 208, which in the illustrated embodiment the food is Frenchfries FF.

[0262] An alternative embodiment for secondary container 210 isillustrated in FIG. 4A. Secondary container 210″ is composed of a pairof opposed spaced apart sidewalls 211′ (only one sidewall 211′ isillustrated and is depicted in a half-moon configuration) and a pair ofsidewalls 213 a and 213 b, oriented in a V-shaped relationship whencontainer 210′ is configured to receive food from conveyor body 214.Sidewall 213 a is mounted for pivotal movement about apex 215 ofsidewalls 213 a and 213 b. Such movement is accomplished by a drivemechanism similar to cylinder 264, drive gear 268 and driven gear 270,which in this embodiment are cylinder 264′, drive gear 268′ and drivengear 270′, which gear 270′ is attached to sidewall 213 a. When cylinder264′ is extended, sidewall 213 a is caused to pivot downwardly asindicated by arrow M to the position of sidewall 213 a shown in phantom,thereby causing the contents (French fries FF) of container 210″ to bedumped. Sidewalls 211′ act as sidewall guides for sidewalls 213 a and213 b when sidewall 213 a is in a lowered position, in which casesidewalls 213 a and 213 b act as a chute or slide.

[0263] The components of lane 1234 will now be described in detail andit is to be understood that the components of lanes 1236 and 1238 aresimilar. Lane 1234 includes uncooked bulk food dispensing container 1204and a food handling system 1242 which in this embodiment is identicalfor each lane 1234,1236, 1238 and 1240 as well as for each lane of fooddispensing device 1201. It should be noted that food handling system1242 and components thereof, as for example, illustrated in FIGS. 76-84is depicted with respect to lane 1234 and that food handling system 1242is generally the same for each lane 1234, 1236, 1238 and 1240 unlessotherwise noted.

[0264] Food handling system 1242 includes conveyor 1208, secondarycontainer 1210, weighing mechanism 1216 and dumping mechanism 1218.Conveyor system 1208 includes vibratory mechanism 1212 and conveyor body1214.

[0265] Uncooked bulk food dispensing container 1204 can be of a shapeand dimension generally as desired and can be similar to container 204previously described. Preferably, uncooked bulk food dispensingcontainer 1204 has an upper opening to permit a supply of food to beplaced in uncooked bulk food dispensing container 1204. Upper opening1244 as illustrated is located in an upper rear portion of uncooked bulkfood dispensing container 1204 and can be conveniently accessed via arear door 1246 of cabinet 1202. Rear door 1246 preferably is insulatedwith suitable insulation material 1224.

[0266] Uncooked bulk food dispensing container 1204 is similar tocontainer 204 previously described.

[0267] Uncooked bulk food dispensing container 1204 includes a bottomopening 1256 that permits the discharge of food contained therein.Bottom opening 1256 can be configured as desired and in the illustratedembodiment the entire bottom of uncooked bulk food dispensing container1204 above conveyor body 1214 is open. In the illustrated embodiment,uncooked bulk food dispensing container 1204 is particularly suited foruse with food such as French fries and chicken nuggets as well as othertypes of food of relatively small size.

[0268] Uncooked bulk food dispensing container 1204 is suitably mountedwithin cabinet 1202, such as described with respect to food dispensingcontainer 204.

[0269] As illustrated in FIGS. 76 and 77, for example, food contained inuncooked bulk food dispensing container 1204 passes through bottomopening 1256 and onto conveyor body 1214 which in the illustratedembodiment is a suitably dimensioned pan. Conveyor body 1214 may have aplurality of spaced apart holes in a bottom portion thereof (shown inFIG. 79 with respect to conveyor 1214′) to permit ice crystals orunwanted small particles of food to pass therethrough so that suchmaterial is not dispensed to fry module 1400. Any suitable or desiredarray of holes or apertures can be utilized as desired. Typically, thehole size will be about 0.25 inches or less and may be about 0.125inches or less. Below and at the downstream bottom end of conveyor body1214 is located secondary container 1210, which is positioned to receivefood items from conveyor body 1214 of conveyor 1208. Conveyor body 1214is suitably mounted to vibratory mechanism 1212 to effect vibration ofconveyor body 1214 as well as food contained therein and food containedin uncooked bulk food dispensing container 1204, and in particular thelower portion of container 1204. This vibration facilitates thedischarge of food from uncooked bulk food dispensing container 1204 andcauses food contained in conveyor body 1214 to travel in the directionof arrow G′. Any suitable conveyor system can be used in accordance withone aspect of the invention. The same type of vibratory mechanism can beused as previously described with respect to vibratory mechanism 212.

[0270] In accordance with another embodiment of the invention, aregulating device which may be an elongated rotatable device, may beprovided at a lower portion of bulk food dispensing container 207 or1204, or otherwise located between the bottom or a bottom portion ofcontainer 207 or 1204 and above or along an upper portion of conveyor214 or 1214. The regulating device limits the quantity of French friesor other food that is delivered to conveyor 214 or 1214 so that conveyor214 or 1214 does not get overloaded or jammed with food items. Such adevice is illustrated in FIGS. 77A and 77B and includes an elongatedvane device 1257, rotatable by a suitable motor device (not shown). Inone embodiment, vane device 1257 can be rotated about 120° in eitherdirection and after rotating, food (e.g., French fries) is caused to bedispensed into conveyor 214 or 1214. When additional food is needed forconveyor 214 or 1214, which can be determined by a suitable sensor,which can be an optical sensor or a load cell associated with conveyor214 or 1214, vane device 1257 is rotated 120° in the motor drive in theopposite direction. The 120° rotation typically is accomplished in about2 seconds, for example.

[0271] As illustrated in FIGS. 77A and 77B, vane device 1257 is composedof three equally spaced apart vanes or paddles 1257 a-c, mounted to acentral triangular section 1259. Vane device 1257 can be convenientlyremoved from bulk food dispensing container 1204 through hinged accessdoor 1261, as illustrated in FIGS. 77A and 77B, which can be opened andclosed by rotation in the direction of arrows OP and CL, respectively. Asupport 1265 for one end of vane device 1257 is provided on an interiorportion of door 1261 as shown in FIG. 77B. A suitable aperture 1263 isprovided through container 1204 for the motor device for vane device1257, as shown in FIG. 77B with vane device 1257 removed.

[0272] Container 1204 can be otherwise similar to container 1204 and canbe constructed of, for example, transparent walls 1267, 1269,1271 and1273 as illustrated in FIGS. 77A and 77B, with front wall 1275 beingmetal or another suitable material.

[0273] Food dispensing device 1200 preferably includes a suitablemechanism to determine the weight or volume of a charge of fooddelivered by conveyor 1208 to secondary container 1210. The amount maybe determined either by weight or volume, for example. In theillustrated embodiment, weighing mechanism 1216 is operativelyinterfaced with secondary container 1210 to provide an indication of theweight of food contained in secondary container 1210. The weight sensedin secondary container 1210 by weighing mechanism 1216 is communicatedwith subcontrol system 1114 of food dispensing device 1200. Subcontrolsystem 1114 is similar to subcontrol system 114 and monitors andcontrols the operative functions of food dispensing device 1200 ashereinafter described in greater detail.

[0274] Optionally, a level sensor can be employed in uncooked bulk fooddispensing container 1204 to provide an indication of the amount of foodstored therein that is available for dispensing. Any suitable levelindicator known in the art can be utilized in accordance with theinvention such as photoelectric, weight, turning fork and others, forexample.

[0275] Secondary container 1210 is a bottomless box-like containerhaving an open top and is composed of generally upstanding sidewalls. Afloor or platform 1222 is stationary and is located beneath container1210 when in the retracted or home position as shown in FIG. 77. In thisposition, container 1210 is able to receive food items from associatedconveyor 1208. An elongated lip or tray 1210′ extends from back wall1210 a of container 1210 so that when container 1210 is in the dumpposition, lip or tray 1210′ is located below the discharge end ofconveyor body 1214 so that any articles of food that may fall from theend of conveyor body 1214 will be collected on lip or tray 1210′ andthose items will be deposited into container 1210 as it is retracted tothe home or filling position. When holes are present in the bottom ofconveyor 1214 or 1214′, a suitably removable catch pan (not shown) islocated between the bottom of conveyor 1214 or 1214′ and the top of lip1210′ so that food particles or ice crystals falling through holes inthe bottom of conveyor 1214 or 1214′ do not land on lip 1210′.

[0276] Secondary container 1210 can be considered as a dump containerand has associated therewith dumping mechanism 1218 for laterally movingsecondary container 1210 to retracted and extended positions relative tostationary floor or platform 1222 as indicated by arrows B′, B″ and B′″in FIGS. 76-78, respectively, sufficiently to open door 1220 and to dumpthe contents of secondary container 1210. Any suitable mechanism can beutilized to effect the desired lateral movement of container 1210 and asillustrated, dumping mechanism 1218 includes a dump cylinder or actuator1264 that is secured to a base 1266. Dump cylinder 1264 can selectivelylaterally translate secondary container 1210 which is secured to dumpcylinder 1264 so that when secondary container 1210 is laterally movedor translated to the left, as illustrated in FIG. 78, secondarycontainer 1210 moves forward to a dumping position. Such movement iscaused by extension of dump cylinder 1264. Similarly, retraction of dumpcylinder 1264 laterally moves secondary container 1210 from the dumpposition to the home or filling position as shown in FIG. 77 wheresecondary container 1210 is ready to receive a charge of food fromconveyor 1208, which in the illustrated embodiment the food is Frenchfries FF.

[0277] An alternative embodiment for conveyor body 1214, conveyor body1214′, is illustrated in FIGS. 79 and 80. Conveyor body 1214′ isparticularly suitable for conveying chicken nuggets and similarly shapedtypes of food items. Conveyor body 1214′ has a tray-like body 1214 a anda discharge end 1214 b and an inlet portion 1214 c. Inlet portion 1214 cincludes an upwardly extending dividing member 1214 d that dividesconveyor body 1214′ into two food inlet passageways 1214 e and 1214 f.As illustrated, dividing member 1214 d is saddle-shaped. Inletpassageways 1214 e and 1214 f merge into a single passageway 1214 gwhich initially is relatively wide at portion 1214 g′ and subsequentlynarrows as passageway 1214 g progresses towards discharge end 1214 b.Such arrangement promotes declumping of the chicken nuggets contained inbulk container 204 or 1204 and permits the chicken nuggets to beconveyed in a single file orientation towards discharge end 1214 b. Thispermits effective dispensing and metering of chicken nuggets into eithersecondary container 210 or 1210. The width of passageway 1214 g afternarrowing is about the width of a single chicken nugget and may slightlyincrease if desired towards discharge end 1214 b if desired. Preferably,passageway 1214 g has a non-linear path and may be serpentine or zigzagas illustrated, which further promotes accurate dispensing of chickennuggets or other similarly shaped food articles, which could include, asnon-limiting examples, breaded shrimp, cheese nuggets and jalapenopoppers.

[0278] Passageway 1214 g may include a plurality of holes 1214 h orperforations through bottom 1214 i of conveyor body 1214′ to permitsmall unwanted ice crystals or food particles to pass therethrough sothat such items are not dispensed to fry module 400 or 1400.

[0279] Referring to FIGS. 81 and 82 there is illustrated the dispensingdoor arrangement in accordance with one embodiment of the presentinvention. As illustrated, one door 1220, 1220 a, 1220 b and 1220 c isprovided for each respective product dispensing lane 1238, 1234, 1236and 1240, respectively. Each of doors 1220, 1220 a, 1220 b and 1220 care hinged at the top to close by gravity and are opened when container1210 associated with a particular one of doors 1220, 1220 a, 1220 b and1220 c is laterally translated by cylinder 1264 to a dumping position asshown in FIG. 78 with respect to door 1220 which has been opened in thedirection of arrow C′.

[0280] Door edge overlapping members 1221 a, 1221 b and 1221 c arehinged to swing open in a manner similar to doors 1220, 1220 a, 1220 band 1220 c. Door edge overlapping members 1221 a, 1221 b and 1221 c areeach associated with the respective adjacent doors 1220, 1220 a, 1220 band 1220 c as illustrated in FIGS. 81 and 82 and are hinged for movementsimilar to that independent of doors 1220, 1220 a, 1220 b and 1220 c,such as in the direction of arrow XX in FIG. 82. The door edgeoverlapping members provide a more complete seal between the sides ofdoors 1220, 1220 a, 1220 b and 1220 c that are not adjacent the ends ofdispensing device 1200, thereby restricting entry of water vapor to theinterior of dispensing device 1200 when doors 1220, 1220 a, 1220 b and1220 c are in a closed position. When one of doors 1220, 1220 a, 1220 band 1220 c open, the adjacent door edge overlapping members 1221 a, 1221b and 1221 c also open as shown in FIG. 81, where the opening of door1220 causes door edge overlapping members 1221 b and 1221 c to open,which can be moved independently of doors 1220, 1220 a, 1220 b or 1220 cas shown in FIG. 82.

[0281] Referring to FIGS. 83 and 84, there are illustrated variousembodiments of a declumping member in accordance with the presentinvention.

[0282] As illustrated in FIG. 83, which is a partial fragmentaryexploded view of dispensing device 1200 showing generally verticallyextending declumping member 1370 comprises a downwardly depending pinthat is attached to a lower portion of bulk dispensing container 1204 orto some other suitable structure. Member 1370 is stationary and extendsdownwardly to a position just above the bottom of conveyor body 1214.Thus, when French fries or other food items are conveyed along conveyorbody 1214 which vibrates, member 1370 is stationary and tends to declumpor break apart a frozen clump or mass of French fries as they vibrateand travel past member 1370.

[0283] Referring to FIG. 84, which is a partial fragmentary explodedview of dispensing device 1200 showing an alternate embodimentdeclumping member 1372 that is attached to the bottom of conveyor body1214 and extends upwardly therefrom. French fries or other food itemsconveyed along conveyor body 1214 will encounter member 1372 which willtend to declump or break apart a clump or mass of French fries as theytravel past member 1372.

[0284] Other configurations of declumping members may be used in placeof members 1370 and 1372. Any structure that tends to declump or breakapart a mass or frozen clump of French fries or similar food can beused.

[0285] Subcontrol system 114 coordinates the operation of the variousfunctions of food dispensing device 200 and/or food dispensing device1200. For example, when food dispensing device 200 or 1200 is ready todump a charge of food from secondary container 210 or 1210 out of fooddispensing device 200 or 1200, subcontrol system 114 activates cylinder222 (only for device 200) to open discharge door 220 thereby permittingthe food charge in secondary container 210 to be dumped by dumpingmechanism 218 through open discharge door 220. Dump cylinder 264 or 1264is extended causing secondary container 1210 of device 1200 to open door1220 and dump the contents therein to fry device 1400. After dumping ofthe food charge is completed, subcontrol system 114 causes dump cylinder264 or 1264 to be retracted thereby returning secondary container 210 or1210 to a position ready to accept a further charge of food fromconveyor system 208 or 1208. For device 200, cylinder 222 has one endrigidly secured to cabinet 202 or some other suitable location and theother end of cylinder 222 is attached to discharge door 220. Typically,discharge door 220 will have a suitable guide mechanism, which may betracks, slots or other suitable apparatus to guide discharge door 220 toits open and closed positions. Cylinder 222 is operable to move door 220up and down as indicated by arrow B in FIG. 6 to thereby open and closedischarge door 220 as desired. In the illustrated embodiment, dischargedoor 220 extends across all four dispensing lanes 226, 228, 230 and 232.If desired, a separate discharge door could be provided for each ofdispensing lanes 226, 228, 230 and 232 such as doors 1220, 1220 a, 1220b and 1220 c previously described. In addition, subcontrol system 114causes activation of cylinder 222, when present, to close discharge door220 to prevent heat from entering into cavity 272 of food dispensingdevice 200 in which the food and various dispensing mechanisms arecontained as illustrated in FIGS. 3 and 6, for example.

[0286] Food dispensing devices 200 and 1200 can contain suitablerefrigeration components 274 such as within a lower portion of cabinet202 as shown schematically in FIG. 1. In accordance with the preferredembodiment of food dispensing devices 200 and 1200, refrigerationcomponents 274 provide sufficient cooling to provide a below freezingtemperature environment in cavity 272. Alternatively, suitablerefrigeration components can be provided exteriorly of cabinet 202 andeven at a remote location as desired. In addition, a storage compartment276 and a storage compartment door 278 may also be provided in cabinet202. An upper side access door may also be provided to permit operatoraccess to the interior of cavity 272 where uncooked bulk food dispensingcontainers 204 and/or magazine food dispensers 206 and/or 209, 211 and213 are located.

[0287] Referring to FIGS. 2 and 7-10, there is illustrated anotherembodiment of food dispensing device 201 in accordance with the presentinvention.

[0288] Food dispensing device 201 has many similarities to fooddispensing device 200 previously described where like reference numeralsrepresent like elements. Thus, food dispensing device 201 includescabinet 202, four product dispensing lanes 226, 228, 230 and 232 witheach such lane incorporating conveyor 208, secondary container 210,vibratory mechanism 212, conveyor body 214, weighing mechanism 216,dumping mechanism 218, discharge door 220, cylinder 222, insulatingmaterial 224, food handling system 242, upper opening 244, rear door246, uncooked bulk food dispensing container 204 which is associatedwith product dispensing lane 234, a dump cylinder 264 for each productdispensing lane, cavity 272, refrigeration components 274, storagecompartment 276 and a storage compartment door 278. Product dispensinglanes 228, 230 and 232 each have associated therewith a plurality ofmagazine food dispensers 280-308 arrayed to provide in the embodimentillustrated in FIG. 9 five magazine food dispensers per productdispensing lane in which there are three product dispensing lanesserviced by the foregoing magazine food dispensers. Consequently,magazine food dispensers are configured in a three-by-five array and aresuspended from a magazine food dispenser support 310 as shown in FIG. 9.Each row of three magazine food dispensers depends from magazine fooddispenser support 310 via a slide assembly 312. Slide assembly 312 issimilar to a drawer slide including a pair of first and second elongatedtelescoping left and right slides 314 and 316, respectively. Suitableupper rollers 318 are mounted to magazine food dispenser support 310 andlower rollers 320 depend from magazine food dispensers 280-308 fortraversing left and right elongated telescoping slides 314 and 316.

[0289] Suitable mounting brackets 322 are provided which depend upwardlyfrom magazine food dispenser support 310 for mounting to cabinet 202.

[0290] In addition, suitable mounting brackets 324 are provided whichdepend downwardly from magazine food dispenser support 310 for mountingslide assembly 312 thereto allowing magazine food dispensers 280-308 todepend therefrom.

[0291] Magazine food dispenser support 310 has a series of holes 326 and328 therein. Holes 326 can be provided to allow increased airflow andcooling. Holes 328 can also be provided to provide increased airflow andcooling for magazine food dispensers 280-308.

[0292] Each of magazine food dispensers 280-308 and 206, 209, 211 and213 briefly discussed with respect to food dispensing device 200 aresimilar in construction. Magazine food dispenser 206 will be discussedwith respect to FIGS. 7 and 8 and it is to be understood that the othermagazine food dispensers are of similar construction.

[0293] Magazine food dispenser 206 includes a body or housing 330 thatincludes sidewalls 332 and 334, front walls 336 and 338 andcorresponding rear walls (not shown) and can be attached in a removablemanner if desired, including in a snap-on arrangement to facilitatecleaning. Magazine food dispenser 206 also includes a top member orcover 340 having mounted thereover a drive mechanism 342. Drivemechanism 342 includes a drive gear or wheel 344 and a driven wheel orgear 346. Depending from each of drive wheel or gear 344 and drivenwheel or gear 346 is a spiral flight that is vertically or generallyvertically oriented relative to the longitudinal axis of spiral flights348 and 350. If desired, a single spiral flight dispenser (not shown)could also be utilized.

[0294] Body 330 of magazine food dispenser 206 can include substantialopen portions such as front open portion 352 and a corresponding rearopen portion (not shown). Such open portions may have a cover or accessdoor thereover (not shown). Such open portions can be desirable topermit airflow through magazine food dispenser 206 since generally suchdispenser will be contained in a refrigerated environment and suchopenings help ensure that food contained therein remains frozen orchilled as desired. A vertical divider (not shown) can be providedbetween spiral flights 348 and 350 if desired.

[0295] A plurality of generally vertically disposed and spaced apartrods 354, 356 and 358 may be provided at the front of magazine fooddispenser 206 adjacent spiral flights 348 and 350 and similar rods canbe provided at the back of magazine food dispenser 206. Rods 354, 356and 358 prevent food pieces from falling out of spiral flights 348 and350 and to maintain spiral flights 348 and 350 in a verticalorientation.

[0296] Magazine food dispenser 206 has an open bottom 360 through whichfood pieces can be dispensed during operation.

[0297] During operation, drive wheel 344 can be driven by a suitableelectric motor, such as an electric motor 362, 364 and 366 shown withrespect to magazine food dispensers 280, 282 and 284 in FIG. 9.Alternatively, other drive devices could be used, including, forexample, a rotary air or hydraulic cylinder. Rotation of drive wheel 344in a clockwise direction causes driven wheel 346 to rotate in acounterclockwise direction by virtue of the intermeshing or contactbetween drive wheel or gear 344 and driven wheel or gear 346. Suchrotation causes corresponding rotation of spiral flights 348 and 350,respectively. Food contained by spiral flights 348 and/or 350 is moveddownwardly by virtue of such rotation. When such food reaches the bottomof spiral flights 348 and/or 350, respectively, such food is dischargedfrom magazine food dispenser 206 through open bottom 360 and ontoconveyor 208 for handling as previously described or onto conveyor 1208,for example. A single motor could be used to drive a plurality ofdispensers 280, 282 and 284, etc. through a suitable drive mechanism(not shown).

[0298] As shown in FIG. 8, pieces of food can be contained by magazinefood dispenser 206 in two different ways. For example, individual piecesof food may each be contained by a single elongated spiral flight 348 or350 as shown with respect to food pieces F1 and F2, respectively. Foodpieces F1 and F2 can be any type of desired food and may be a food itemsuch as a hash brown, an individual portion pie, rectangular food patty,or other type of food as desired. Chicken nuggets and other food canalso be dispensed with the bulk dispenser previously described. Largeritems of food can span across portions of both elongated spiral flights348 and 350 as illustrated with respect to food item F3, which may be alarger food item, such as a chicken patty, or other type of food articleas desired. Spiral flights 348 and 350 can be of a desired radialdiameter so that the food piece or pieces that are to be contained anddispensed in magazine food dispenser 206 can be accommodated asillustrated in FIG. 8. Each spiral can contain a food piece so that asillustrated in FIG. 7, the illustrated spirals of spiral flights 348 and350 could each accommodate twelve food pieces such as food pieces F1 orF2 for a total of twenty-four food pieces or twelve food pieces such asfood piece F3 of FIG. 8. As will be appreciated, spiral flights having agreater or lesser number of flights can be used if desired to hold agreater or lesser number of food pieces, respectively.

[0299] A suitable home position sensor 362′ can be utilized to indicatea home or start position of each of spiral flights 348 and 350. Asillustrated in FIG. 7, a pair of position indicating sensors 362′ and364′ are utilized and mounted on drive wheel 344 180° apart for moreprecise locating of the position of spiral flights 348 and 350. Sensors362′ and 364′ can be proximity sensors that align with correspondingsensor pickups on the respective drive gear or motor for magazine fooddispenser 206 (not shown).

[0300] Preferably, spiral flights 348 and 350 are offset by one rotationso that a single food item such as food item F1 or F2 in FIG. 8 will bedispensed from one of either spiral flight 348 or 350 for each one-halfrotation of spiral flights 348 and 350.

[0301] Food dispensing devices 1200 and 1201 may incorporate magazinedispensers such as magazine dispensers 280-308 as previously described.Thus, dispensing device 1200 has a one-by-five array of magazinedispensers, such as magazine dispenser 206 and dispensing device 1201incorporates magazine dispensers 280-308 as previously described fordispensing device 201. Food dispensing devices 1200 and 1201 utilize theconveyor system and food dump mechanism as previously described withrespect to dispensing device 1200.

[0302] Preferably, food dispensing devices 200 and 1200 and fooddispensing devices 201 and 1201 are constructed in modular form, anexample of which is illustrated in FIGS. 1 and 74 and 2 and 75,respectively. Wheels 368 can be provided to permit cabinets 202, 402 and602 to be suitably transported across a relatively flat surface, such asa restaurant work area floor.

[0303] In accordance with another embodiment of the invention fordispensing modules 200 and 1200, a magazine dispenser, such as magazinefood dispenser 1206 can be oriented horizontally instead of vertically.Such a horizontally oriented magazine dispenser can be configured todischarge food items onto an inclined chute contained within the freezercompartment or cavity of dispenser 200 or 1200 (for example cavity 272of device 200) to receive dispensed food items, which chute ispositioned with a discharge end oriented to deposit the food itemsdirectly into secondary container 210 of dispensing device 200 orsecondary container 1210 of dispensing device 1200. Thus, the vibratingconveyor need not be used. The chute may be constructed in any suitableconfiguration, such as, for example, as non-limiting examples, chute498, 1603 or 1554, as illustrated in FIGS. 12, 74 and 85, respectively.In addition, a single spiral flight, such as spiral flight 348, may beused in the horizontal orientation instead of two spiral flights.

[0304] An example of the foregoing embodiment is illustrated in FIGS.77C and 77D. As illustrated therein, a magazine dispensing device 1300is provided for the dispensing of individual food items, and is orientedhorizontally, forming part of food dispensing module 1302. Food itemsare conveyed by a single spiral conveyor 1304 for each spiral magazine1306 a-c in the direction of arrow SS. Each spiral magazine 1306 a-c isdriven by a suitable motor 1308 or other suitable drive mechanism. Aftera food item is dispensed from one of spiral magazines 1306 a-c, the fooditem falls in the direction of arrow TT and onto inclined chute 1310.The food item then travels down chute 1310 in the direction of arrow UUand into secondary container 1312, which is similar to secondarycontainer 1210, except rear wall 1314 is slightly inclined. The otherindicated elements are similar to dispensing module 1210 or otherelements previously described, as indicated by the reference numeralstherein. Thus, no vibrating conveyor is used in this embodiment for thedispensing of food items from the spiral conveyor, as the food itemstravel to secondary container 1312 by gravity after being dispensed fromone of spiral magazines 1306 a-c.

[0305] In addition, a suitable sensor (not shown) may be utilized tosense or count the number of food articles being dispensed from thespiral flight or flights. The sensor can be any suitable type including,as non-limiting examples, either an ultrasonic or an optical sensor,which are well known in the art, or by weighing, such as a load cell.

Food Frying Device

[0306] Referring to the Figures generally, and in particular to FIGS.1-2 and 11-24, there is illustrated fry device 400 and variouscomponents and alternative components thereof in accordance with theinvention.

[0307] In one embodiment, fry device 400 includes cabinet 402, four frywheels 404, 410, 412 and 414, four fry vats 406, 416, 418 and 420, fourdrive mechanisms 408, one for each of fry wheels 404, 410, 412 and 414.Each fry vat 406, 416, 418 and 420 is dimensioned to contain a desiredvolume of a suitable cooking oil. Each fry vat 406, 416, 418 and 420 isdedicated to one of fry wheels 404, 410, 412 and 414, respectively.

[0308] In operation in the preferred embodiment, fry device 400 ispositioned to receive the food dispensed from a food dispensing device,such as food dispensing device 200 and food dispensing device 201.Consequently, it is advantageous to position fry device 400 adjacentfood dispensing device 200 or 201 as illustrated in FIGS. 1 and 2,respectively. A suitable control panel 456 can be provided and locatedin a suitable location, such as on the side of cabinet 402. In theillustrated embodiment, control panel 456 contains a separate displayfor each of fry wheels 404, 410, 412 and 414 referred to by referencenumerals 456 a-d, respectively. Control panels and displays 456 a-d caninclude information such as set cycle time, oil temperature, oil levelas well as controls to adjust cycle time and oil temperature, forexample.

[0309] Referring to FIG. 13, there is illustrated fry wheel 410. Frywheel 410 includes two opposed circular spaced apart circular disks 458a and 458 b. Disks 458 a and 458 b can include a plurality of apertures460 as desired to reduce wheel weight and to provide circulation ofcooking oil and to permit passage of water vapor therethrough, such asduring frying food products, for example. A fry wheel axle 462 isprovided to which disks 458 a and 458 b are mounted. Axle 462 issuitably mounted, typically and preferably for rotation with respect tofry vat 406 at a location above the normal level of cooking oil or rangeof levels of cooking oil that will be encountered in fry vat 406 duringoperation.

[0310] In one embodiment, outer peripheral edge 464 of each of disks 458a and 458 b include a plurality of teeth 466.

[0311] Teeth 466 can be utilized to drive fry wheel 410 in a manner ashereinafter described. Referring to FIGS. 14-16, there is illustrated insectional view of disk 458 a of fry wheel 410, a portion of which islocated within fry vat 406. A drive wheel 468 is associated in operativeposition relative to teeth 466 located on outer peripheral edge 464 ofdisk 458 a. Drive wheel 468 can be formed from a disk of material of asuitable thickness having a circumferential groove 470 therein.Circumferential groove 470 is typically at least or slightly greaterthan the thickness of disk 458 a in the area where drive wheel 468 anddisk 458 a are juxtaposed as illustrated in FIGS. 14 and 15. A series ofspaced apart pins 472 extend across circumferential groove 470 and areradially arrayed and spaced from the center of drive wheel 468. Drivewheel 468 includes a central aperture 474 through which a drive axle 476can be mounted. In operation, drive wheel 468 is rotated by drive axle476 with drive wheel 468 being positioned a fixed distance from disk 458a so that pins 472 mesh with teeth 466 when rotated as illustrated inFIG. 14 thereby causing rotation of disk 458 a and consequently frywheel 410 in a direction of rotation opposite to the rotation of drivewheel 468, as indicated by arrows K and L of FIG. 14.

[0312] It is to be understood that any suitable drive wheel and drivearrangement can be utilized. For example, in place of drive wheel 468with pins 472, a drive arrangement could be utilized in which a drivegear is utilized to mesh with a corresponding gear located around theperiphery of disk 458 a and/or 458 b, for example. Alternatively, afriction drive system could be utilized in which a friction drive wheelwould contact the edge of one or both of circular disks 458 which couldbe of a design having no teeth therealong, such as illustrated inalternative embodiment wheels 479 and 481 described hereafter. Since thewheel will have cooking oil thereon, the coefficient of friction betweenthe drive wheel and fry wheel will be decreased. Care should be taken toassure that when using a friction drive, sufficient pressure ismaintained between the driving wheel and the fry wheel.

[0313] Referring to FIG. 16, there is illustrated a drive mechanism fordriving drive wheel 468. The drive mechanism includes an electric motor478, a gear reduction drive 480, an output shaft 482, a drive pulleywheel 484, a driven pulley wheel 486 and a drive belt 488 extendingaround drive pulley wheel 484 and driven pulley wheel 486 to drive axle476 which thereby drives drive wheel 468 since the end 476a of axle 476is fixed in aperture 474 with respect to drive wheel 468. A shear pin490 can be located in a shear pin aperture 492 of drive wheel 468 toretain axle 476 in a fixed position relative to drive wheel 468. Axle476 is suitably contained within an axle journal 494 which, in turn, ismounted to frame 496 to permit movement of axle 476 relative to axlejournal 494 and frame 496. Similarly, motor 478 and gear reduction drive480 are suitably mounted to frame 496. If desired, motor 478 may be astepper motor.

[0314] Typically, it is important that the fry wheel is rotated inperiodic increments for a compartment to be aligned with a respectivedischarge slide 498 of fry device 400 or other slide, ramp or dischargelocation after a periodic rotation. Typically, the leading edge 500 of acompartment bottom, such as compartment bottom 432′ of compartment 432as shown in FIG. 13 is aligned with the upper edge of fry vat 406 or thetop edge of discharge chute 498 associated therewith to allow thecontents of compartment 432 to be discharged therefrom. As illustratedin FIG. 13, the contents of compartment 432 have already been dischargedfrom fry wheel 410. This is particularly important where incrementalrotation of fry wheel 410 is utilized as opposed to a continuouslymoving fry wheel. Thus, for incremental rotation it is desirable forleading edge 500 of compartment 432 to be aligned with discharge 498 orthe upper edge 406′ of fry vat 406. In order to accomplish this, astepper motor can be utilized to drive fry wheel 410. Alternatively, orin addition, the position of the baskets can be sensed and theirposition adjusted accordingly to assure that all baskets are in thecorrect position for loading and discharge during operation. Also,utilizing location sensors allows use of a simple DC or AC motor, asopposed to a stepper or servo motor. Any suitable sensor can be utilizedin conjunction with a control system to control operation of the frywheel drive motor. Suitable sensors include proximity, magnetic reed,Hall Effect, photoelectric and capacitive sensors. Such sensors are wellknown in the art and consequently a detailed description of thosesensors is not included herein.

[0315] In accordance with another aspect of the invention, it should beunderstood that the height of cooking oil in one of fry vats 406, 416,418 and 420, such as the level of cooking oil indicated by referenceletter H in FIG. 13 in fry vat 406 will increase or decrease dependingupon the amount of food that is submerged underneath the surface ofcooking oil contained in fry vat 406. Thus, as illustrated in FIG. 13,compartments 424, 426, 428 and 430 each have a charge of food, in thiscase French fries 455 contained therein. Each compartment containsapproximately one pound of French fries 455. Consequently, there areabout four pounds of French fries that are beneath the surface level Hof cooking oil contained in fry vat 406. This quantity of submerged foodraises the level H of cooking oil in fry vat 406. This increase in thelevel of cooking oil can cause the food to be submerged and thereforecooked for a longer of period of time in the cooking oil. For example,contrast the level of cooking oil depicted in FIG. 13 with the level ofcooking oil depicted in FIG. 20 in which a charge of French fries 455 iscontained only within compartment 426. This results in a substantiallyreduced level of cooking oil H′ as indicated in FIG. 20. Thus, thecontrol system for fry device 400 can be adjusted to take into accountfor different levels of cooking oil which can be sensed by a suitablesensor as is known by those skilled in the art (not shown). Whererotation of fry wheel 410 is done incrementally after a period of timeelapses, the period between incremental rotations can be increased ordecreased as desired based on the level of cooking oil present in fryvat 406. For example, in the situation illustrated in FIG. 13, theduration between incremental rotation of fry wheel 410 could bedecreased compared to the situation depicted in FIG. 20 where the levelH′ of cooking oil is significantly lower than the level H of cooking oilin FIG. 13. This assumes that the temperature of cooking oil in each ofthe situations depicted in FIGS. 13 and 20 is substantially the same.Similarly, if a constant rotation fry wheel operation is utilized, suchas where fry wheel 410 would rotate constantly, the rotational speedcould be increased to handle the situation depicted in FIG. 13 comparedto the speed of the wheel that would be utilized for the situation inFIG. 20, where the level H′ of cooking oil in FIG. 20 is significantlyless than the level H of cooking oil in FIG. 13.

[0316] Referring to FIGS. 13 and 20, frying device 400 can also includea fry wheel follower “or fry wheel liner” 502 which is supported by afry wheel follower support 504. Fry wheel follower 502 is a curvedperforated circular segment having a width approximately equal to thewidth of fry wheel 410. Fry wheel follower 502 is supported by a pair offry wheel follower supports 504 that are spaced apart and connected bylateral supports 506. Fry wheel follower 502 prevents food pieces thatare larger than the perforations in fry wheel follower 502 from fallingfrom fry wheel compartments 422-436 during operation. Preferably, theperforations in fry wheel follower 502 are composed of circular holeshaving a diameter of about 0.187 inches that are in staggered rowshaving a center-to-center hole distance of about 0.312 inches. Fry vat406 includes a suitable heating element 505, illustrated in FIGS. 13, 20and 21.

[0317] Referring to FIGS. 17-19 there is illustrated a curvedcompartment forming member 438 which is composed of two opposedsidewalls 508 a and 508 b that are interconnected by a perforated curvedcompartment forming member 510 that forms compartment bottom 510 a andcompartment top 510 b. Preferably, a wiper 512 is suitably mounted tocompartment forming member 510.

[0318] A plurality of compartment forming members 438 are mountedtogether in fry wheel 410 to provide a plurality of adjacent peripheralfood compartments 422-436 as illustrated in FIG. 13. As illustrated inFIG. 13, the top of one compartment forming member 510 abuts the bottomof adjacent compartment forming member 510. Thus, advantageously, afastening member 514, which can be a rivet, for example, that secureswiper 512 to compartment bottom 510 a of one compartment forming member510 will also pass through the compartment top 510 b of the adjacentcompartment forming member 510. Preferably, wiper 512 has a plurality oftransversely extending grooves 516 a-f that permit drainage of cookingoil therethrough as wiper 512 exits the cooking oil in fry vat 406, forexample.

[0319] Referring to FIG. 17, opposed sidewalls 508 a,b and compartmentforming member 510 are perforated to permit the flow of cooking oiltherethrough thereby promoting good heat transfer between the cookingoil contained in fry vat 406 and food contained in one of compartments422-436 when immersed in cooking oil. A suitable hole size is about0.156 inches spaced center-to-center about 0.250 inches. Wiper 512 alsoensures that close contact is maintained between the interface of frywheel follower 502 and the top and bottom ends of each food compartment422-436 which in each case will be bounded by one of wipers 512. Anysuitable material can be used for wiper 512 such as rubber or Teflon®,for example. A magnet may be incorporated into wiper 512 for use inconjunction with a reed switch to determine compartment location.Alternatively, a ferrous edge on compartment bottom 510, for example,for use with a modified reed switch that is fitted with a magnet As analternative construction, compartments 422-436 could be constructed fromcompartment forming members 510 without opposed sidewalls 508 a and 508b, in which case the compartment sidewalls could be formed from opposedcircular disks 458 a and 458 b. In addition, it should be appreciated byone skilled in the art that any desired compartment shape can beutilized in accordance with the invention as long as the food can beloaded into the compartment, kept within the compartment duringimmersion in the cooking oil and which compartment shape discharges thefood from the fry wheel.

[0320] Referring to FIGS. 21 and 22, there are illustrated furtheraspects of fry device 400. FIG. 21 is a sectional view along line 21-21of FIG. 20. FIG. 21 illustrates the elements previously described and inaddition shows the interface of adjacent fry vats 406 and 420 and inenlarged form in FIG. 22. Disposed between fry vats 406 and 420 is abanking strip 518 that bridges the gap between fry vats 406 and 420.Banking strip 518 can be in a shape as desired and in the illustratedembodiment is a generally inverted V-shaped strip that spans the gapbetween fry vats 406 and 420. Banking strip 518 prevents any materialthat is discharged between fry wheels 410 and 412 from falling betweenfry vats 406 and 420 and causing such material to fall into one of fryvats 406 and 420.

[0321] Referring to FIGS. 23 and 24, there are illustrated alternateembodiments of a fry wheel for use in accordance with the invention. Itis to be understood that the fry wheel is capable of numerous changesand rearrangements, and the fry wheel, as well as other components andembodiments of the present invention, is not intended to be limited tothe specific embodiments described herein.

[0322] Referring to FIGS. 23 and 24, there are illustrated wire formwheels 479 and 481. Each of wheels 479 and 481 has a rim 520 and 522,respectively, constructed of tubing, which can be smooth tubing. Such awheel could be driven by a friction wheel, if desired. In each of wheels479 and 481 a plurality of individual tubular spokes 524 extend fromeach rim to a corresponding hub assembly 526. An axle 528 connects hubs526 together in each of wheels 479 and 481. Wheel 479 includes a slottedmember 530 that bridges each pair of spokes 524. Each slotted member 530includes a centrally disposed slot 532 and a pair of tabs 534 on eitherside of slot 532. A plurality of fry baskets 536, one for each slottedmember 530 or pair of spokes 524 is mounted in a snap-lock relationshipto each slotted member 530. Fry baskets 536 have perforated sides and aperforated bottom and top and can be of a similar configuration aspreviously described with respect to fry wheel 410. Each basket 536 canhave a spring tab member 538 that interlocks with slotted member 530 tosecure fry basket 536 to fry wheel 479 resulting in a finished fry wheel481 as shown in FIG. 24. It is to be understood that the embodimentillustrated in FIGS. 23 and 24 is not limited to snap-in baskets andthat other baskets can be used with the wheel arrangement depicted inFIG. 23 with or without slotted members 530. For example, baskets couldbe welded or otherwise affixed to rim 520 and spokes 524. Each of frybaskets 536 includes perforations 540 on the sides, top and bottomthereof, such as previously described with respect to compartmentforming member 438.

[0323] Referring to FIG. 24, there is illustrated an alternative drivemechanism 535 to rotate fry wheel 481. Drive mechanism 535 includes amotor 537, a shaft 539 and drive rollers 541 and structure for supplyinga force in the direction of arrow FW. Drive rollers 541 are mounted onshaft 539 which can be rotated by motor 537 to cause rollers 541, eachaligned with one of rims 522, to rotate, thereby rotating fry wheel 481.A force FW is supplied in the direction of arrow FW to ensure thatrollers 541 impart a sufficient tractive force to cause rotation of frywheel 481. Force FW can be supplied by any suitable structure, includinga spring, a weight or an electromagnet, for example. For example, motor537, shaft 539 and rollers 541 could be mounted on a platform (notshown) that is movable in the direction of arrow FW and a force could beapplied to urge the platform in the direction of arrow FW to ensureproper traction of rollers 541. Rollers 541 may be constructed of anysuitable material, including rubber, for example. Motor 537 can becontrolled by subcontrol system 116, for example.

[0324] Fry wheel 410 can be rotated as desired so that food deposited inone of compartments 422-436 travels through and out of the cooking oil454 until that compartment reaches a discharge location. Thus, in theembodiment illustrated in FIGS. 13 and 20, the rotation is in aclockwise direction as indicated by arrow K in FIG. 13 and arrow K inFIG. 20. The rotation of fry wheel 410 can be either continuous orperiodic. In a periodic rotation, the rotation will typically beincremental, that is, the wheel is rotated to some degree and thenstops. Thereafter, after a set period of time, the wheel undergoesanother periodic rotation. This process continues as each fry basket isrotated through and out of the cooking oil vat and to the dischargelocation. Preferably, each periodic rotation consists of a rotation of360° divided by the number of compartments present in the fry wheel orsome fraction of that periodic rotation increment so that the positionof the wheel can be known without the use of sensors. However, the useof a sensor or sensors to be able to monitor wheel position can also beused either as the primary way of controlling wheel position or as abackup. Also, use of a sensor to determine wheel position allows use ofa standard AC or DC motor. Suitable control of wheel 410 can beaccomplished by fry control 116, for example.

[0325] In accordance with the present invention, a basket shakingsimulation can be achieved. Basket shaking simulation can be performedby a relatively slight back and forth rotation of the fry wheel, such asfry wheel 410. Thus, the drive mechanism is activated to rotate the frywheel clockwise and counterclockwise through a relatively small degreeof angular rotation to simulate shaking of a fry basket during frying.The back and forth rotation can occur relatively rapidly and typicallythe degree of angular rotation will be in the range of from about 2 toabout 20 degrees. In addition, the periodic rotation in one directionmay be of a larger angle of rotation than the rotation in the otherdirection.

[0326] Preferably, the degree of rotation during simulated basketshaking will be monitored, particularly where the rotation in onedirection is greater than the rotation in the other direction so thatthe position of each basket relative to the discharge location can bemonitored by the control system to ensure proper discharge of food fromfood compartments.

[0327] Referring to FIG. 64, there is illustrated in partially schematicview fry device 400 along with portions of food dispensing device 200and food packaging device 600. As illustrated in FIG. 64 a hood system546 is provided. Hood system 546 includes a hood structure 548, a filter542 and a drip pan 544.

[0328] A suitable air blower (not shown) can be provided to cause airflow to move within hood system 546 generally in the direction of arrowsA1, A2 and A3. Filter 542 thus filters particulate matter in air flow Althat passes through filter 542. Drip pan 544 catches any matter thatdrips from filter 542 that is located above drip pan 544. Preferably,hood system 546 substantially completely encloses the area above frydevice 400 to reduce waste discharge into the operating environment ofautomated food processing system 100.

[0329] Fry module 1400 is similar to fry module 400 previously describedand can be operated and controlled as described with respect to frymodule 400. In addition, control system 1116 for fry module 1400 issimilar to control system 116 previously described.

[0330]FIG. 85 illustrates a fragmentary perspective view of a portion offry module 1400,which includes a foam deck 1550 and an overflowpassageway 1552. Foam deck 1550 is located below food inlet slide orchute 1554 to fry module 1400, which is disposed to receive food itemsfrom dispensing module 1200 or 200, for example, and into one ofcompartments 422-436 of fry wheel 410. Thus, foam deck 1550 is locatedabove the normal operating level of frying oil in fry vat 406 and is onthe food inlet side of fry module 1400 adjacent inlet slide or chute1554. Overflow passageway 1552 is an elongated slot that can be routedto a drain or waste container as indicated by arrow WW. Typically, whena quantity of food, particularly frozen, is placed in a fry vat, foamingoccurs in the hot oil that contains water. Some of the foam is collectedon the foam deck and drains through the overflow passageway, therebyeliminating some of the foam and water that results from the initialcharging of food to fry module 1400.

Food Packaging Device

[0331] Referring to the Figures generally, and in particular to FIGS. 1,25-50, 74, 76 and 86-91, there are illustrated various embodiments offood packaging devices and elements thereof in accordance with theinvention.

[0332] In one embodiment, food packaging device 600 is illustrated orpartially illustrated and elements useful in connection with foodpackaging device 600 are illustrated in FIGS. 1 and 25-50. Foodpackaging device 600 includes a cabinet 602 having a countertop surface636. Food packaging device 600 can be advantageously constructed inmodular form so that it can be operated together with previouslydescribed food dispensing device 200 and fry device 400 andalternatively operated separately from both or either of those devices.

[0333] Food packaging device 600 in the illustrated embodiment includesa food inlet chute 604, rotatable food dispensing member 606, fooddispensing chute mechanism 608, automated container handling system 610,container-receiving receptacle 612, overflow food collection member 613,conveyor system 614, waste chute 615, food seasoning system 616 andraceway 620.

[0334] In the illustrated embodiment, food packaging device 600 includesa container storage device for containing cartons or containers ofvarious sizes. During operation of packaging device 600, the deviceselects a container of a desired size from container storage magazine638, erects the container into an erected form that is unerected whilecontained in storage magazine 638 and then positions the erectedcontainer to receive food dispensed from food dispensing chute mechanism608. After receiving food from food dispensing chute mechanism 608,automated container handling system 610 is capable of moving the filledor partially filled container to container receiving receptacle 612which is transported via conveyor system 614 to a desired location forsubsequent pickup of the container by a human operator, for example.

[0335] In the embodiment illustrated in FIGS. 25-29, food packagingdevice 600 includes food overflow collection member 613 to collect fooddispensed by food dispensing chute mechanism 608 that is not depositedinto a container. In the illustrated embodiment, overflow foodcollection member 613 is a rotatable wheel as hereinafter described indetail. Overflow food collection member 613 functions to collect fooddispensed by food dispensing chute mechanism 608 that is not received ina container and to recycle that food into food dispensing chutemechanism 608 for subsequent dispensing to a container. This permitsfood dispensed by food dispensing chute mechanism 608 but not depositedin a container to be promptly recycled to the dispensing chute in afirst-in, first-out manner, so that overflow food is promptly recycledand dispensed to a container.

[0336] Referring to FIGS. 26-28, there is illustrated food packagingdevice 600 in which inlet chute 604 is positioned to receive food, inthis case French fries, from food dispensing lanes 234, 236 and 238 ofdispensing device 200, which food has been subsequently fried afterdispensing in fry wheels 410, 412 and 414 of fry device 400. Afterfrying in any of wheels 410, 412 and 414 of fry device 400, fooddispensed therefrom enters inlet chute 604, as illustrated in FIGS. 3and 28, for example. In inlet chute 604 the food travels downwardlyalong chute 604 and into rotatable food dispensing member 606 in thedirection of arrow M of FIG. 28 and arrow E of FIG. 3. Inlet chute 604can be configured as desired and may be configured to accept the productfrom any one or all of fry wheels 404, 410, 412 and 414. In FIGS. 25-27,a holding area 607 receives product from fry wheel 404 for manualpackaging. A manual or automated diverter bar 605 can optionally beprovided as shown in FIG. 27 to divert French fries from device 600 topermit filling unsalted fry orders. Bar 605 can be moved between openand closed positions as indicated by arrow Z, such as by a cylinder (notshown).

[0337] Rotatable food dispensing member 606 in the illustratedembodiment is a dispensing wheel that is mounted for rotation indispensing device 600. Dispensing member 606 has a plurality of foodcontaining compartments 640 that are arrayed around the periphery ofrotatable food dispensing member 606. Each of compartments 640 isdivided from another compartment by a compartment wall 642. Preferably,each compartment wall 642 is not normal to peripheral edge 644 ofrotatable food dispensing member 606 but at a slight angle such as, forexample, as illustrated in FIG. 29 and FIG. 61.

[0338] Wheel 606 includes a pair of opposed rim portions 646 a and 646 band a circular ring portion 648 that interconnects opposed rims 646 aand 646 b. Circular ring 648 is disposed close to the peripheral edgesof rims 646 a and 646 b and defines peripheral edge 644. Preferably,circular ring 648 is constructed of a perforated metal material so thatcircular rims 646 a and 646 b have perforations 650 therethrough asillustrated in FIG. 28, for example.

[0339] In accordance with the illustrated embodiment, rotatabledispensing member 606 is configured as a rotatable wheel although otherembodiments are within the scope of the invention. For example, arotatable dispensing member in accordance with the invention could be aportion of a wheel, such as a semicircular or other configuration.

[0340] In the illustrated embodiment, rotatable food dispensing member606 is rotated by a drive mechanism 652. Drive mechanism 652 consists ofa motor 654 that drives a drive wheel 656. Drive mechanism 652 iscontrolled by a suitable control mechanism to cause rotation of drivewheel 656 and hence moves rotatable food dispensing member 606 in adesired direction and at a desired rate of speed. Drive wheel 656 can bea pressure roller or alternatively can be a drive wheel like or similarto drive wheel 468 previously described with respect to FIG. 14.Rotatable food dispensing member 606 can be driven via one or both ofopposed rims 646 a and 646 b. Alternatively, and as illustrated in FIG.28, rotatable food dispensing member 606 is driven through a drive rim658. Each of rotatable food dispensing members 606 and overflow foodcollection member 613 rest on spaced apart rollers 660 and 662. Each ofrollers 660 and 662 are constructed to bear the weight of rotatable fooddispensing member 606 and overflow food collection member 613 and have alength that spans both. Alternatively, separate rollers or some othersupporting structure could be used to support rotatable food dispensingmember 606 and overflow food collection member 613. An inner curvedfender or baffle member 664 as illustrated in FIG. 29 is provided toensure that food contained in compartment 640 of rotatable fooddispensing member 606 does not prematurely discharge. Preferably, fender664 follows the inner curvature of rotatable food dispensing member 606and has perforations 666, which can be similar to perforations 650 ofcircular ring 648. Fender 664 is suitably mounted so that it isstationary relative to rotatable food dispensing member 606. A similarfender could also be provided for overflow food collection member 613,if desired (not shown).

[0341] Referring to FIG. 61, there is illustrated an elevation view of aportion of rotatable food dispensing member 606 which is typicallyrotated in the direction of arrow Y when viewed from the front of foodpackaging device 600. Fender 664 prevents food, in this case Frenchfries FF, from falling from compartments 640 prematurely.

[0342] Overflow food collection member 613 is configured to collect fooddeposited from food dispensing chute mechanism 608 that is intended tobe received into container 611 when held in position to receive foodfrom food dispensing chute mechanism 608 which food does not stay incontainer 611. This can occur since oftentimes it is desirable tooverfill container 611 so that food is mounded up above the top surfaceof container 611. Also, for food such as French fries, such foodmaterial fills container 611 somewhat randomly and it is typical forFrench fries to dangle over the sides of container 611. In theillustrated embodiment, overflow food collection member 613 isconfigured in a manner similar to rotatable food dispensing member 606previously described. Thus, food collection member 613 includes opposedrims 668 a and 668 b and circular ring 670 having perforations 672.Circular ring 670 connects opposed rims 668 a and 668 b in a manner aspreviously described with respect to member 606. In addition, foodcollection member 613 has a plurality of inner compartments that aresimilar in construction to compartment 640 previously described withrespect to member 606. Member 613 also has a drive rim 674 and is drivenby a drive mechanism 676 that is similar to drive mechanism 652previously described including a drive wheel 676′ and a motor 678. Drivemechanism 676 is configured to rotate food collection member 613 ineither a clockwise or counterclockwise direction as hereinafterdescribed in more detail.

[0343] Food collection member 613 also includes a plurality ofcompartment walls 680 that are similar to compartment walls 642previously described with respect to rotatable food dispensing member606, providing a plurality of food containing compartments 682.

[0344] Each of food dispensing member 606 and food collection member 613has bottom portions that are disposed through an opening 684 incountertop surface 636 of cabinet 602. The construction of theillustrated embodiment permits food dispensing member 606 and overflowfood collection member 613 to be readily removed from food packagingdevice 600 such as for cleaning and/or repair.

[0345] A heating system as described can be incorporated into foodpackaging device 600 to supply heat to food contained therein. Forexample, a heating system 681 can be provided, which is illustrated inFIG. 29. Heating system 681 includes a heating device 683 having aheating element 685, located above dispenser 606 as desired. Heatingdevices 687 and 689 may also be included within dispenser 606 and/or 613as desired. The heating devices may comprise radiant heaters and can beceramic heaters, for example. Any suitable type of heating device orsystem can be used in accordance with the invention. Heating system 681can be controlled by subcontrol system 118, for example. In addition, aheating device can be provided to direct heat to food container pick uplocation 622, if desired to keep food contained thereat warm.

[0346] Referring to FIGS. 1, 3, 25-26, 28-29 and 43-44, various aspectsof the configuration and operation of food dispensing chute mechanism608 are illustrated and will be described. Food dispensing chutemechanism 608 includes an upper chute 686, a lower chute 688, a chutesupport member 690, a connecting link 692, a stop member 694, arotatable link 696 connecting stop member 694 to chute support member690, a rotatable link 698 connecting upper chute 686 to support member690, a cylinder 700 for operating food dispensing chute mechanism 608, aload cell 702 for weighing the contents of food contained in fooddispensing chute mechanism 608 and a rotatable link 704 connectingcylinder rod 706 to upper chute 686.

[0347] Upper chute 686 preferably and as illustrated in the referencedfigures, forms part of food dispensing chute mechanism 608, and has aninlet location 708 for receiving food dispensed from rotatable fooddispensing member 606 and a discharge location 710 for dispensing foodcontained in food dispensing chute mechanism 608 and into a container,such as container 611 as illustrated in FIG. 43, for example.

[0348] Upper chute 686 of food dispensing chute mechanism 608 ispositioned to receive pieces of food from a discharge location 712 ofrotatable food dispensing member 606. Upper chute 686 has a food holdingarea 714 for holding food received from rotatable food dispensing member606. A weighing device is associated with food dispensing chutemechanism 608 so that the amount of food contained therein, such as infood holding area 714, can be determined. Any suitable device can beutilized to determine the amount of food contained in food dispensingchute mechanism 608. In the illustrated embodiment, a load cell 702 isprovided to determine the weight of food contained in food dispensingchute mechanism 608 and is illustrated schematically in FIGS. 43 and 44,for example.

[0349]FIG. 44 illustrates food dispensing chute mechanism 608 in theupper position ready to receive food from rotatable food dispensingmember 606. In that configuration, cylinder 700 is retracted and upperchute 686 is generally horizontal. This configuration allows a quantityof food to be dispensed into upper chute 686 and into food holding area714 without being dispensed therefrom. When a sufficient quantity offood is deposited in upper chute 686, such as French fries FF, asdetermined by load cell 702 which communicates with the control systemof food packaging device 600, the food contained therein is ready to bedispensed. Typically, the amount of food contained in chute 686 will besufficient to adequately fill container 611. Since container 611 is of aknown size, rotatable food dispensing member 606 can be operated tosupply food to chute 686 until a desired quantity is contained thereinfor dispensing to container 611.

[0350] To dispense food from food dispensing chute mechanism 608,cylinder 700 is activated to extend cylinder rod 706 upwardly therebycausing upper chute 686 to drop. Since lower chute 688 is connected toupper chute 686 via connecting link 692, lower chute 688 also drops tothe discharge position as illustrated in FIG. 43 which movement isindicated by arrow S. Stop 694 which is connected to lower chute 688 andpivotally mounted via rotatable link 696 to chute support member 690,engages chute support member 690 as illustrated in FIG. 43 and preventsfurther downward movement of upper chute 686 and lower chute 688. Inaddition, stop member 694 engaging chute support member 690 defines thelowermost position of upper chute 686 and lower chute 688 which is alsothe dispensing position of food dispensing chute mechanism 608, asillustrated in FIG. 43. This position also provides discharge location710 of dispensing chute mechanism 608.

[0351] Referring to FIGS. 25-28, there is illustrated container storagemagazine 638, which can form part of food packaging device 600.Container storage magazine 638 is configured to store a plurality ofdifferent sized food containers in an unerected form. Typically,container storage magazine 638 will be configured to hold a variety ofdifferent sized containers. In the illustrated embodiment, containerstorage magazine 638 can contain four different sizes of French frycontainers or cartons. Container storage magazine 638 includes a base716 that is suitably mounted with mounting structure 718 to cabinet 602.Preferably, mounting structure 718 permits container storage magazine638 to be readily removed to permit access to rotatable food dispensingmember 606 and overflow food collection member 613.

[0352] Base 716 typically can be in the form of a base plate andincludes four apertures 720, 722, 724 and 726, each of said aperturescorresponding to the profile of a different size collapsed carton.Apertures 720, 722, 724 and 726 are dimensioned to be able to retain astack of cartons in a collapsed or unerected condition as illustrated inFIG. 25 in which a plurality of unerected cartons 728 are stackedtherein.

[0353] Each aperture 720, 722, 724 and 726 and base 716 has associatedtherewith a plurality of guide members 730-760. In the illustratedembodiment, guides 730-760 are in the form of post or tubular-typemembers. Each set of four guide members is associated with a specificone of apertures 720, 722, 724 and 726 to define and permit stacking ofa plurality of unerected French fry cartons or containers that generallycorrespond in size to the size of apertures 720, 722, 724 and 726,respectively. It is to be understood that other arrangements to define acontainer stack can be utilized in accordance with the invention. Forexample, in place of guides 730-760 other structure could be utilized,such as upstanding walls or partial walls or other types of guides.

[0354] Container storage magazine 638 may also include a suitableremovable cover (not shown) to enclose base 716 and the volume definedover apertures 720-726 by guides 730-760.

[0355] Container storage magazine 638 is preferably positioned to permitready access to the bottom of each container stack through the bottom ofeach of apertures 720-726 by automated container handling system 610,which is hereinafter described in detail.

[0356] Food packaging device 600 includes automated container handlingsystem 610. Automated container handling system 610 is capable ofretrieving an unerected container through any of apertures 720, 722, 724and 726 of unerected container storage magazine 638, erecting theunerected carton, holding the erected carton in position at dischargelocation 710 of food dispensing chute mechanism 608 and depositing thefilled container onto conveyor system 614, which conveyor system 614subsequently transports the filled container to a desired location.

[0357] Referring to FIGS. 1, 25, 27-28 and 30-44, there is illustratedautomated container handling system 610 and elements and featuresthereof. Automated container handling system 610 includes a containerretrieving and grasping device 762, a container grasping device 764 anda container bottom urging device 766.

[0358] Automated container handling system 610 is controlled by asuitable control system for food packaging device 600.

[0359] Container retrieving and grasping device 762 and portions thereofare best illustrated in FIGS. 30-39. Container retrieving and graspingdevice 762 includes a mast 768, which is mounted to a carriage system770, a movable rack member 772, a pinion 774, a frame 776, a containergrasping member 778 and a linkage assembly 780.

[0360] Mast 768 is carried by carriage system 770 which carriage system770 allows for lateral translation of mast 768 and the componentsassociated therewith, including movable rack member 772, pinion 774,frame 776, container grasping member 778 and linkage assembly 780.Carriage system 770 includes a guide member 782, a worm gear 784, adrive mechanism 786 and a carriage follower 788. Carriage follower 788supports a vertical translation mechanism 790 that, in turn, carriesmast 768.

[0361] Carriage guide 782 is an elongated guide that defines the lateraltranslation movement direction of carriage follower 788 and is securedwithin cabinet 602. Worm gear 784 is disposed parallel to carriage guide782 and when rotated moves carriage follower 788 along carriage guide782.

[0362] Worm gear 784 is driven by drive mechanism 786 which can includea drive motor 792, a drive gear or pulley 794 and a driven gear orpulley 796. Where drive and driven pulleys are used, typically a belt798 will impart rotation from one pulley to another.

[0363] Drive motor 792 drives driven pulley 796 and causes worm gear784, which is mounted for rotation, to be rotated by rotation of drivenpulley or gear 796 in either direction. Drive motor 792 can be an AC orDC motor or a stepper or servo motor as desired. Suitable sensors can beemployed (not shown) to determine the position of carriage follower 788which determines the lateral position of container grasping member 778.

[0364] Carriage follower 788 is composed of a frame 800 having a guideaperture or slot 802 in which carriage guide 782 is disposed and athreaded aperture or slot 804 in which elongated worm gear 784 isdisposed to impart lateral motion to carriage follower 788 by rotationof worm gear 784. Thus, carriage system 770 provides lateral movement inthe direction of arrows Q as shown in FIG. 39. In this manner, carriagefollower 788 and thus mast 768 can be laterally translated as desired.

[0365] A suitable opening 806 is located in countertop surface 636 ofcabinet 602 to permit mast 768 to extend therethrough.

[0366] Mast 768 can be raised and lowered in a vertical direction asindicated by arrow V in FIG. 39.

[0367] Mast 768 can be vertically raised and lowered in the directionsindicated by arrow V in FIG. 39 by operation of a drive mechanism 810that forms part of vertical translation mechanism 790. Verticaltranslation mechanism 790 is a vertically extending carriage systemsimilar to that described with respect to carriage system 770 andincludes a drive mechanism 810 which is composed of a motor 812 which iscarried by carriage follower 788, a vertically disposed carriage guide814, a vertically disposed worm gear 816 which is driven in a suitablemanner by motor 812 such as previously described with respect to drivemechanism 786 of carriage system 770, which can be controlled in asimilar manner. Vertical translation mechanism 790 also includes avertical carriage follower 818 having a threaded aperture or slot and aguide aperture or slot (not shown) which vertical carriage follower 818is secured to mast 768.

[0368] Mast 768 has mounted thereto frame 776, typically at an upper endthereof. Linkage assembly 780 is secured to frame 776 as well as pinion774 and movable rack member 772.

[0369] Movable rack member 772 includes a frame 820 having a guide slot822 vertically disposed therein and a rack 824 which meshes with pinion774. Movable rack member 772 may also include extra mass in the form ofa weight block 826 to help urge movable rack member 772 downwardly whennot restrained.

[0370] A pair of guides 828 and 830 are rigidly secured to frame 776 andare disposed within slot 822 of movable rack 772. A spring 832 can beconnected between an upper end of movable rack member 772 and guide 828or 830 to urge movable rack member 772 to a lower position asillustrated in FIG. 30 compared with the upper position as illustratedin FIGS. 34-37.

[0371] In a preferred embodiment, movable rack member 772 includes astop 834 which stop can be vertically adjustable. While stop 834 islocated at the bottom of movable rack member 772 it is to be understoodthat a stop could be provided at another location provided that asuitable engaging surface at a proper location is provided.

[0372] Mounted to frame 776 is an axle 836 that is mounted for rotationrelative to frame 776. Axle 836 has pinion gear 774 rigidly securedthereto as well as one end 838 of linkage 780. The other end 840′ oflinkage 780 is securely mounted to frame 776 as illustrated in FIGS.30-37, for example.

[0373] Linkage 780 which carries container grasping member 778 iscomposed of a plurality of links so that container grasping member 778is movable from a horizontal position as illustrated in FIGS. 30-32 to avertical position as illustrated in FIGS. 34-37. When container graspingmember 778 is in the horizontal position it is utilized to grasp andretrieve a desired size of container from one of the apertures 720, 722,724 and 726 from container storage magazine 638. For this purpose,container grasping member 778 includes a suction cup device 840 whichincludes at least one suction cup 842 and in the illustrated embodimenttwo suction cups 842 and 844 arrayed in substantially the same plane forgrasping a container having a surface to be grasped by both suction cups842 and 844 in the same plane. Suction cup device 840 also includes avacuum source 846, a release valve 848 and a suitable vacuum line 850which connects suction cups 842 and 844 to vacuum source 846, asillustrated in FIG. 30, for example. In operation, when suction cups 842and/or 844 engage a container or other member to be grasped, vacuumsource 846 is activated to supply vacuum to suction cups 842 and 844,such as to grasp and retain a container from one of apertures 720, 722,724 and 726 of container storage magazine 638.

[0374] Linkage assembly 780 includes, in the illustrated embodiment, afirst link 852, a second link 854 and third link 856.

[0375] First link 852 is rigidly secure to axle 836 and pinion 774.First link 852 is configured in an L-shape with the end of first link852 opposite the portion connected to axle 836 pivotally connected tosecond link 854 having one end being pivotally connected to first link852 via pivot connection 858.

[0376] Second link 854 is connected to third link 856 via a universaljoint connection 860 a location spaced apart from pivot connection 858as illustrated in, for example, FIGS. 30-37. Section cups 842 and 844are mounted to second link 854. An offset member 862 which depends fromsecond link 854 provides a desired offset for universal joint connection860 which connects second link 854 to third link 856.

[0377] Third link 856 is, in turn, connected to frame 776 via auniversal joint connection 864 which is at a distance removed fromuniversal joint connection 860 which connects third link 856 to secondlink 854. An offset member assembly 866 is rigidly secured to frame 776and includes an angled block 868 and an offset extension 870 to providethe desired angled and clearance for universal joint 864 and third link856.

[0378] In operation, when movable rack member 772 is moved relative tomast 768, such as when stop 834 contacts a surface, such as in theillustrated embodiment, countertop surface 636 as illustrated in FIG.36, continued downward vertical movement of mast 768 causes rack member772 to move upwardly relative to mast 768. This causes rotation ofpinion 774 which meshes with rack 824 mounted to rack member 772.Rotation of pinion 774 in a counter-clockwise direction in FIG. 30causes rotation of first link 852. Such rotation causes downwardmovement of that portion of first link 852 that is pivotally connectedto second link 854 via pivot connection 858. Such movement, in turn,causes second link 854 to pivot upwardly about pivot connection 858 in aclockwise direction as viewed in FIG. 30 to cause suction cups 842 and844 to move to a vertically oriented position as depicted in FIGS. 34-37from the horizontally oriented position depicted in FIGS. 30-33. Inaddition, such movement of first link 852 causes movement in rotation ofthird link 856 and universal joint connection 860 and 864 to theposition indicated in FIGS. 34-37. When container grasping member 778 isin the position indicated in FIGS. 34-37, an unerected container held bysuction cups 842 and/or 844 will be vertically oriented when suctioncups 842 and/or 844 are attached to the container sidewall, asillustrated in FIG. 40, for example.

[0379] In a typical operation, container retrieving and grasping device762 will be operated to position suction cups 842 and 844 below acontainer to be selected from container storage magazine 638. Mast 768will be raised by operation of vertical translation mechanism 790 to adesired height so that suction cups 842 and 844 engage a containercontained at the bottom of container storage magazine 638. Vacuum source846 is activated and mast 768 can be lowered to remove a container froma desired one of apertures 720, 722, 724 and 726 of container storagemagazine 638. Carriage system 770 can be activated to move containerretrieving and grasping device 762 laterally to a desired location. Suchlateral movement can be controlled by properly positioned sensors 872,874, 876, 878 and 880, for example. For example, sensor 872 can definethe position to retrieve a container from aperture 720, sensor 876 toretrieve a container from aperture 722, sensor 878 to retrieve acontainer from aperture 724 and sensor 880 to retrieve from aperture726. Sensor 874 can be positioned to define the proper location ofcontainer grasping member 778 to erect the container that has beenretrieved from one of apertures 720, 722, 724 or 726 of containerstorage magazine 638, as hereafter described. After erecting thecontainer, the vacuum applied to suction cups 842 and 844 is released byoperation of release valve 848 which permits suction cups 842 and 844 todisengage and release the container that had been grasped. Mast 768 canthen be raised causing stop 834 to be removed from countertop surface636 and by action of weight 826 and operationally spring 832, causingrack member 772 to move downwardly relative to mast 768 thereby rotatingpinion gear 774 clockwise relative to the position shown in FIG. 34,thereby moving linkage assembly 780 to cause movement of containergrasping member 778 from the position illustrated in FIGS. 34-37 to theposition indicated in FIGS. 30-33, where container grasping member 778is in position to retrieve a desired carton from container storagemagazine 638 in a manner previously described, which includes lateraltranslation of container grasping member 778 by carriage system 770.

[0380] It is to be understood that any suitable automated device orsystem for retrieving, grasping and moving a container to a desiredlocation as desired herein can be utilized in accordance with variousaspects of the present invention. Thus, various aspects of the presentinvention are not limited by the particular embodiment of containerretrieving and grasping device 762 and components thereof describedherein. For example, an automated or robotic arm could be utilized toselect, grasp and retrieve erected or unerected containers from a sourceas desired and then erect the carton or container in a suitable manner,followed by holding the erected container at discharge location 710 andafter filling placing the filled container, such as container 611 on toa suitable conveyor to move the filled container to a desired location.

[0381] Container grasping device 764 of container retrieving andgrasping device 762 will now be described, and in particular withreference to FIGS. 38 and 40-44.

[0382] Container grasping device 764 includes a rotatable and verticallytranslatable mast 884. Mast 884 can be rotated as illustrated by arrow Pin FIG. 38 and vertically translated up and down as indicated by arrow Oalso in FIG. 38. Mast 884 is connected to a shaft 886 via a slot and keyarrangement between mast 884 and shaft 886 permitting mast 884 to berotated by shaft 886 which, in turn, can be rotated by a stepper motor890 or other suitable motor or device to rotate shaft 886 a desireddegree. Motor 890 drives a drive pulley or gear 892 which, in turn,drives a driven pulley or gear 894. In the case where pulleys areutilized, a belt 896 is used to transmit rotation from pulley 892 topulley 894. Motor 890 can be a stepper motor or a servo motor asdesired. Alternatively, an AC or DC motor can be utilized provided thata suitable control is provided so that the orientation of mast 884 canbe determined. A carriage system 898 is utilized to provide the desiredvertical movement of mast 884 in up and down directions. Carriage system898 is similar to carriage system 770 previously described and includesa carriage guide 900, a worm gear 902, a carriage follower 904, a drivemechanism 906 which includes a motor 908 (which can be a servo motor oran AC or DC motor) suitably controlled to drive worm gear 902. Carriagefollower 904 includes a threaded aperture or slot 910 which communicateswith worm gear 902 and a threaded aperture or slot 912 in which guide900 is disposed. A carriage follower interface 914 connects carriagefollower 904 to mast 884 and permits shaft 886 to rotate with respect tocarriage follower interface 914. Thus, in operation, rotation of motor908 rotates worm gear 902 thereby translating carriage follower 904 upor down depending on the direction of rotation. A suitable sensor (notshown) can be employed to determine the height of mast 884 for controlby subcontrol system 118 for packaging device 600.

[0383] Suitable mounting structure 916 is provided to mount containergrasping device 764 to a desired location, such as within cabinet 602. Aslot and key arrangement between shaft 886 and mast 884 permits 884 mastto be vertically translated either up or down while shaft 886 isrotated.

[0384] Mounted on the upper end of mast 884 is a suction device 918which includes a suction cup 920, a source of vacuum (not shown) forsuction cup 920 and a release valve (not shown) for releasing the vacuumto suction cup 920. Vacuum can be supplied from within mast 884 tosuction cup 920 by a suitable connection as is known in the art.

[0385] Container bottom urging device 766 consists of a mast 922 that isvertically translatable up and down by suitable apparatus (not shown).Such apparatus can be similar to vertical translation mechanism 790previously described with respect to container retrieving and graspingdevice 762. Preferably, mast 922 has a blunt end 924.

[0386] In operation, container retrieving and grasping device 762selects an appropriately sized container from container storage magazine638 as directed by the control system for food packaging device 600.After retrieving the container, which in this case is container 611,container retrieving and grasping device 762 moves container 611 to aposition as indicated in FIG. 40 against suction cup 920 so that opposedsidewalls of container 611 are grasped by suction cups 840 and 842 ofcontainer grasping member 778.

[0387] Next, as shown in FIG. 41, container grasping member 778 is movedlaterally away from suction cup 920 while maintaining suction on suctioncups 840, 842 and 920. Container 611 is partially erected as shown inFIG. 41 with bottom 611 b depending downwardly slightly. Containerbottom urging device 766 is then activated as illustrated in FIG. 42 tourge bottom 611 b of container 611 upwardly into the fully erectedposition. Container grasping member 778 is released and retracted fromcontainer 611 and returned to a horizontal up position to select anotherunerected container for erection.

[0388] Next, mast 884 is rotated approximately 900 by motor 890 to placecontainer 611 in discharge position 710 of food dispensing chutemechanism 608. Food dispensing chute mechanism 608 is then lowered todischarge French fries FF therefrom and into container 611. Any Frenchfries that are not received into container 611 are collected by overflowfood collection member 613 which is then rotated clockwise in thedirection of arrow X as shown in FIG. 41 to recycle such French fries toupper chute 686 for subsequent delivery to another container. After theFrench fries are dispensed from food dispensing chute mechanism 608,cylinder 700 is retracted placing food dispensing chute mechanism 608 inthe upper position as shown in FIG. 44. Mast 884 can then be rotatedback and forth slightly (e.g., such as 2° to 20°, for example) tosimulate shaking to dislodge any loose French fries or dangling Frenchfries in container 611 and any dislodged French fries will then fallinto overflow food collection member 613 for subsequent recycling. Mast884 can also be raised and lowered slightly and relatively quicklyeither before, during or after the angular rotation to further simulateshaking. Thereafter, mast 884 is rotated approximately 180° untilcontainer 611 is directly over container-receiving receptacle 612 asindicated by T in FIG. 44. Mast 884 is then lowered by operation ofcarriage system 898 until the bottom of container 611 rests incontainer-receiving receptacle 612. Then, the vacuum supplied to suctioncup 920 is released and suction cup 920 releases from container 611.Mast 884 can then be rotated 90° so that it is in position to receiveanother container to be erected.

[0389] Container-receiving receptacle 612 is then transported viaconveyor system 614 which will now be described in detail.

[0390] Conveyor system 614 and portions or elements thereof areillustrated in various figures including FIGS. 1, 25-29 and 45-50.

[0391] Conveyor 614 includes, in the illustrated embodiment, raceway 620which can be formed along the surface of countertop 636 or on some othersurface as desired. Raceway 620 is preferably in the form of acontinuous loop raceway and is defined by spaced apart guides 620 a and620 b mounted to countertop 636 to guide receptacles 612. Conveyorsystem 614 includes one or more and typically a plurality ofcontainer-receiving receptacles 612 which are illustrated in detail inFIGS. 46-50. Gate structure 634 of conveyor system 614 includes a firstgate 926 and second gate 928. First gate 926 is movable and typicallysecond gate 928 can be stationary as hereinafter described.

[0392] Conveyor system 614 also includes structure for causing movementof container-receiving receptacle 612. In the illustrated embodiment,container-receiving receptacles 612 are moved via an endless loop 930that can be located beneath countertop 636. Endless loop 930 carries aplurality of magnets 932 as illustrated in FIGS. 45 and 49, for example.Magnets 932 are spaced along endless loop 930. Endless loop 930 maycomprise a chain or other suitable structure that can be driven by adrive system that includes sprockets 934, 936, 938 and 940. One ofsprockets 934, 936, 938 and 940 can be a driven sprocket.

[0393] Any suitable endless loop 930 can be utilized such as a belt or achain. Pulleys could be used in place of sprockets 934-940. The route ofendless loop 930 follows the route of raceway 620.

[0394] Container-receiving receptacle 612 typically includes a base 942and a container-receiving well 944 located over base 942. Base 942includes an enclosed compartment 946 which can be conveniently accessedby a base plate 948 located along the bottom of base 942 that isfastened to base 942 by suitable fasteners 950. Contained withinenclosed compartment 946 is a magnet 952.

[0395] Container-receiving receptacle 612 follows the movement of magnet932 due to magnetic attraction between magnets 932 and 952 therebycausing movement of container-receiving receptacle 612 along raceway620.

[0396] Enclosed compartment 946 is dimensioned to permit magnet 952 tobe free to rotate therein allowing container-receiving receptacle 612 tobe readily guided by rails 954 and 956 that are raised above countertop636.

[0397] Movable gate 926 prevents movement of container-receivingreceptacle 612 located thereat as illustrated in FIG. 45. This ensuresthat container-receiving receptacle 612 is in position to receive aloaded container of French fries, such as container 611 from containergrasping device 764. After a filled container is placed oncontainer-receiving receptacle 612 adjacent movable gate 926, gate 926is automatically removed by a suitable mechanism (not shown) to permitcontainer-receiving receptacle 612 thereat to be moved by conveyorsystem 614 until French fry container 611 contained therein contactsgate 928 or receptacle 612 contacts another receptacle that is locatedat pick up area 622 as shown in FIG. 45. Once container 611 is movedfrom receptacle 612 b, receptacle 612 b is then free to move alongraceway 620 and passes underneath second gate 928, which can be astationary gate. Alternatively, second gate 928 could be a movable gateand could be located at a level that directly prevents movement ofreceptacle 612 b. After receptacle 612 b passes underneath second gate928, receptacle 612 a is moved into the position formerly occupied byreceptacle 612 b provided that receptacle 612 a has a French frycontainer thereon which would then cause receptacle 612 a to be stoppedat gate 928. Similarly, when that container is removed from receptacle612 a, receptacle 612 a would then be free to pass underneath gate 928and around that portion of raceway 620 until encountering gate 926 oranother receptacle that is stopped by gate 926.

[0398] Referring to FIGS. 51-60, there are illustrated various views ofFrench fry cartons that are useful in accordance with the presentinvention. The French fry cartons depicted in FIGS. 51-60 areparticularly suitable for use in conjunction with the present inventionsince the cartons readily stand upright without assistance and can beerected by automated container handling system 610, previouslydescribed.

[0399]FIG. 51 illustrates a front elevation view of a carton 1012 thatis particularly suitable for containing French fries, for example.Carton 1012 is illustrated in FIG. 51 in an erected or opened positionand includes a pair of opposed curved sidewalls 1014 and 1016 and abottom panel 1018.

[0400] Carton 1012 can be stacked in a collapsed configuration andstored in a suitable magazine, such as container storage magazine 638 aspreviously described. When in a collapsed position, carton 1012 isparticularly suited to being opened or erected by pulling sidewalls 1014and 1016 apart and urging bottom panel 1018 upwardly, as described withrespect to the erection or opening of container 611 by automatedcontainer handling system 610. Container or carton 611 is of a designthat is similar to carton 1012.

[0401] Carton 1012 also includes two supporting legs 1020,1022 thatextend downwardly from the lower portions of the overlapping edgeportions of sidewall 1014 indicated by reference numerals 1014 a and1014 b in FIG. 59 and FIG. 53.

[0402] Carton 1012 is capable of standing on its own because of legs1020 and 1022 that extend below bottom panel 1018 when carton 1012 isopen or erected.

[0403] Carton 1012 can be constructed from a single blank of paperboardwhich is illustrated in FIG. 59. When constructed, sidewall edgeportions 1014 a and 1014 b form flaps that are glued to the edges ofsidewall 1016 as indicated in FIG. 54, for example.

[0404] Bottom panel 1018 is specially configured to facilitate openingor erection of carton 1012 by an automated carton handling device suchas automated container handling system 610, previously described indetail. Bottom panel 1018 includes intersecting lines 1024 and 1026.Intersecting lines 1024 and 1026 intersect at a generally centrallocation of bottom panel 1018, which panel is generally oval even thoughit may incorporate straight edges 1028 and 1030, for example.Intersecting lines 1024 and 1026 may be fold lines, lines of weakening,score lines or even perforations. All such structures are referred toherein with respect to intersecting lines 1024 and 1026 of bottom panel1018 only as “fold lines.” Typically, the intersection of fold lines1024 and 1026 form an angle in the range of from about 60° to about120°. In one embodiment, the intersecting bottom panel fold lines areoriented such that one of said lines (fold line 1024 in FIG. 59) isnormal or at least generally normal to curved sidewalls 1014 and 1016.In such embodiment, the other of the intersecting fold lines (in thiscase fold line 1026) is at least generally parallel to curved sidewalls1014 and 1016.

[0405] Preferably, fold line 1024 extends from sidewall 1014 to sidewall1016.

[0406] As previously mentioned, carton 1012 is foldable to a collapsedposition with sidewalls 1014 and 1016 being planar and in contactingoverlying relation to each other with bottom panel 1018 being dividedinto two overlying panels 1018 a and 1018 b by intersecting fold line1026.

[0407] Preferably, bottom panel 1018 includes two additional fold lines1032 and 1034 on either side of fold line 1024 that extend from onecarton sidewall to the other, in this case from sidewall 1014 tosidewall 1016. Secondary fold lines 1032 and 1034 further facilitate theopening or erection of container 1012 with an automated device such asautomated container handling system 610.

[0408]FIG. 58 illustrates a carton 1036 that is similar in constructionto carton 1012 previously described except that carton 1036 is of adifferent size. Preferably, carton 1012 is configured such that thewidth of the base is relatively narrow and the sidewalls 1014 and 1016flare outwardly so that container 1012 is substantially wider at the top(from about 1.6 to 2 or more times the base width). This allowsrelatively large and tall containers to be placed in an automobile cupholder CH as depicted in FIG. 56.

[0409] Referring to FIG. 2, there is illustrated an alternate embodimentof an automated food processing system 101 in accordance with theinvention. Automated food processing system 101 includes a fooddispensing device 201 which is similar to food dispensing system 200,previously briefly described, where like reference numerals representlike elements. Food dispensing device 201 includes fewer uncooked bulkfood dispensing containers 204 and additional magazine food dispensersthat are similar to magazine food dispenser 206, previously referred to.Otherwise, dispensing device 201 is similar to dispensing device 200previously described.

[0410] Automated food processing system 101 also includes fry device 400which has been described.

[0411] One primary distinction between automated food processing system100 and automated food processing system 101 is that automated foodprocessing system 101 does not include an automated packaging devicesuch as automated packaging device 600. In place of food packagingdevice 600, a food storage device 635 is provided. Food storage device635 allows food cooked by food frying device 400, to be stored in aheated environment for subsequent manual processing. As configured inFIG. 2, food storage device 635 includes separate product receivingreceptacles 637, 639, 641 and 643. Each receptacle 637, 639, 641 and 643is dedicated to receiving food from a respective one of fry wheels 410,412, 414 and 404, respectively. In addition, each receptacle 637-643 canhave placed therein a suitable container to receive food, such ashandled trays 645, 647, 649 and 651.

[0412] As illustrated in FIG. 2, a food item F is being discharged fromfry wheel 414 down a chute 653 and into handled tray 649 containedwithin heated receptacle 641. Food item F can be stored therein for aperiod of time until it is ready for subsequent processing.

[0413] Referring to FIGS. 62 and 63, there is illustrated heatedreceptacle 643 in a cross-sectional view and FIG. 63 is across-sectional view taken along line 63-63 of FIG. 62 showing theentire width of receptacle 643.

[0414] As illustrated in FIGS. 62 and 63, heated receptacle 643 is aheated well having a heating element that heats sidewalls 962, 964, 966and 968 as well as bottom 970 of heated receptacle 643. Heating element960 is in close proximity to walls 962, 964, 966 and 968 as well asbottom 970. Heating element 960 may be composed of a single heatingelement or multiple heating elements as desired. Suitable controls maybe provided to adjust the temperature of walls 962-968 as well as bottom970 of heated receptacle 643. In addition, suitable insulation 972 canbe contained within the cavity that is defined by cabinet 974 of foodstorage device 635, which is partially shown in FIGS. 62 and 63.

[0415] Preferably, handled trays 645-651, such as handled tray 651depicted in FIGS. 62 and 63 are dimensioned such that they are in closeproximity to walls 962-968 and bottom 970 when placed in heatedreceptacle 643.

[0416] Tray 651 may be constructed of any suitable material. Inaddition, a wire basket which can include a handle may be used as aninsert for tray 651, in which case food CN is contained in the wirebasket and tray 651 functions to collect excess oil from food CN, inwhich case tray 651 desirably would not include a handle.

[0417] Food packaging device 600 may optionally include food seasoningdevice 616, which is illustrated in detail in FIGS. 65-68. Foodseasoning device 616 includes a hopper 972, a metering wheel 974, awheel drive system 976, a dispensing tube 978 and a dispensing head 618.

[0418] Hopper 972 is configured to hold a desired bulk quantity of aseasoning material, such as salt S. Bulk hopper 972 includes a lid 982that can be removed to replenish the supply of salt S contained therein.Hopper 972 can have a bottom with inwardly extending sidewalls 984 tofacilitate the dispensing of material from bottom 986 of hopper 972which may include a dispensing tube 988.

[0419] Metering wheel 974 is located beneath bottom 986 and dispensingtube 988 to receive a charge of salt or other seasoning therefrom.Metering wheel 974 includes a cavity 990 for receiving a charge of saltfrom dispensing tube 988. Metering wheel 974 is rotatably mounted in ahousing 992 and can be rotated about the longitudinal axis of meteringwheel 974 to cause cavity 990 to be directed downwardly which therebycauses the seasoning or salt contained in cavity 990 to fall by gravitytherefrom.

[0420] Metering wheel 974 is suitably rotated by wheel drive system 976.Wheel drive system 976 can be controlled by a suitable electroniccontrol system that can form part of the food packaging device 600.Typically, in operation, when French fries FF are dispensed from one ormore of fry wheels 404, 410, 412 and 414 onto chute 604, a suitablesensing device (not shown) senses the presence of French fries andactivates wheel drive system 976 of automated food seasoning device 616to discharge a predetermined quantity of seasoning, such as salt, ontothe French fries that traverse chute 604.

[0421] Dispensing head 618 can be located in a desired position to applyseasoning to the food traversing chute 604. As illustrated in FIG. 3,for example, dispensing head 618 can be located towards a bottom portionof inlet chute 604 and may extend over a portion of rotatable fooddispensing member 606.

[0422] Wheel drive system 976 as illustrated in FIGS. 65-68 includes asolenoid plunger 994 for driving a linkage 996 that is connected tometering wheel 974 to impart rotation to metering wheel 974. Linkage 996includes a crank arm 998, one end of which is connected to a centralportion of metering wheel 974 and the other end is connected to a leverarm 1000 which, in turn, is connected to solenoid plunger 994. Lever arm1000 can be driven by solenoid plunger 994 which, in turn, causes crankarm 998 to be driven, thereby rotating metering wheel 974 sufficientlyto cause cavity 990 to be directed downwardly, thereby permitting anyseasoning or salt contained therein to be dispensed therefrom.

[0423] A collection funnel 1002 is disposed at the discharge end ofhousing 992 and connects to dispensing tube 978. Dispensing tube 978 is,in turn, connected to dispensing head 618.

[0424] Dispensing head 618 can include a plurality of vanes 1004 forfacilitating dispersion of seasoning dispensed therefrom. Asillustrated, there are four vanes 1004 spaced 90° from each other.

[0425] Dispensing tube 978 has a lower end portion 1006 that terminatessome distance above dispensing cone 1008 of dispensing head 618. In oneembodiment, lower end portion 1006 of dispensing tube 978 may terminateapproximately 0.25 inches from the tip of dispensing cone 1008.

[0426] Dispensing cone 1008 includes a plurality of holes 1010 that arearrayed through dispensing cone 1008 to facilitate the distribution ofseasoning or salt. In operation, as salt or seasoning is dispensedthrough lower end portion 1006 of dispensing tube 978, the seasoningstrikes the top portion of dispensing cone 1008 and is directed intofour quadrants via vanes 1004. As the seasoning traverses the surface ofdispensing cone 1008, some of the seasoning falls through holes 1010 indispensing cone 1008. Note that not all of holes 1010 are labeled, forpurposes of clarity in the Figures. Other salt or seasoning particles donot fall through holes 1010 but fall off the lower end of dispensingcone 1008. Still other seasoning particles bounce or are otherwisedeflected off the top surface of dispensing cone 1008 and fall a lateraldistance removed from dispensing cone 1008. In this manner, a gooddistribution of seasoning is achieved over a relatively large area.

[0427] In one embodiment, food packaging device 1600 is illustrated orpartially illustrated and elements useful in connection with foodpackaging device 1600 are illustrated in FIGS. 74, 76 and 86-91. Foodpackaging device 1600 includes a cabinet 1602, inlet chute 1604, saltingdevice 1606, holding bin 1612, container filling device 1614, containerhandling system 1622 and elevator 1628. Food packaging device 1600 canbe French fry containers or cartons or other containers as desired.

[0428] Referring to FIGS. 86-89B, there is illustrated container storagemagazine 1630, which can form part of food packaging device 1600.Container storage magazine 1630 is configured to store a plurality ofdifferent sized food containers, in this case French fry cartons in anunerected form. Typically, container storage magazine 1630 will beconfigured to hold a variety of different sized containers. In theillustrated embodiment, the containers are individual portion-sized andare of a type having opposed sidewalls connected by a collapsiblecontainer bottom. Typically, the rear sidewall extends higher than thefront sidewall. Such containers are well known in the art and variousnon-limiting examples are illustrated at FIGS. 51-60. In the illustratedembodiment, container storage magazine 1630 can contain four differentsizes of containers.

[0429] Container storage magazine 1630 of container handling system 1622includes a base 1632 that is suitably mounted to cabinet 1602.Preferably, container storage magazine 1630 is mounted to be readilyremoved to permit replacement and/or repair and to otherwise permitaccess to other portions of packaging device 1600.

[0430] As illustrated, magazine 1630 is composed of four individualmagazines 1630 a-d, although any desired number can be used. Eachmagazine 1630 a-d includes a face plate 1636 a-d defining apertures 1638a-d, respectively, each of said apertures corresponding to the profileof a different size collapsed carton. Apertures 1638 a-d are dimensionedto be able to retain a horizontal stack of cartons in a collapsed orunerected condition as illustrated in FIGS. 86-88 in which a pluralityof unerected cartons C-C′″ are stacked therein.

[0431] Each face plate 1636 a-d and each aperture 1638 a-d hasassociated therewith a plurality of generally horizontally extendingguide members 1640 a-d shown with respect to face plate 1636 dconsisting of four members each, for maintaining uniform stacks ofunerected cartons. In the illustrated embodiment, guides 1640 a-d are inthe form of L-shaped elongated members. Each set of four guide membersis associated with a specific one of apertures 1638 a-d to define andpermit horizontal stacking of a plurality of unerected French frycartons or containers that generally are slightly larger in size thanthe size of apertures 1638 a-d, respectively. It is to be understoodthat other arrangements to define a container stack can be utilized inaccordance with the invention. For example, in place of guides 1640 a-dother structure could be utilized, such as upstanding walls or partialwalls or other types of guides.

[0432] Container storage magazine 1630 typically will also include asuitable urging device for each magazine 1630 a-d to urge the stack ofcontainers contained therein against respective face plates 1636 a-d indirection ZZ of FIGS. 89A and 89B, which may be a spring loaded urgingdevice. Each magazine 1630 a-d includes a restraining member 1642 a-d,respectively, for restraining the rear sidewall from relative movementwith respect to the front sidewall. As illustrated, restraining members1642 a-d are in the form of an arcuate spring clip. In addition, a pairof horizontally extending guides 1644 a-d are provided adjacentapertures 1638 a-d to guide cartons as they are removed from magazine1630 and erected.

[0433] Container storage magazine 1630 is preferably positioned topermit ready access to the front of each container stack through each ofapertures 1638 a-d by container handling system 1622, which ishereinafter described in detail.

[0434] Food packaging device 1600 includes container handling system1622. Container handling system 1622 is capable of retrieving anunerected container through any of apertures 1638 a-d of containerstorage magazine 1630, erecting the unerected carton and placing theerected carton in position on elevator 1628 for delivery to containerfilling device 1614.

[0435] Referring to FIGS. 74, 86, 88-89, there is illustrated containerhandling system 1622 and elements and features thereof. Containerhandling system 1622 includes a container retrieving and grasping device1646 that includes a container grasping device 1648, X-carriage system1650, Y-carriage 1652 and container bottom urging devices 1653 a-d,which are in the form of inclined ramps located adjacent apertures 1638a-d. Any suitable container handling device that performs the functionsof system 1622 can be used, in whole or in part as desired.

[0436] Container handling system 1622 is controlled by a suitablecontrol system for food packaging device 1600, similar to the controlsystem for packaging device 600 as hereafter described.

[0437] Container retrieving and grasping device 1646 and portionsthereof are best illustrated in FIGS. 86-89C. Container grasping device1648 includes a carriage follower body 1654, which is mounted toX-carriage system 1650, Y-carriage 1652, a Y-carriage follower 1666 anda container grasping member 1648.

[0438] Body 1654 is carried by X-carriage system 1650 that includes andis driven in a suitable manner such as a toothed belt 1660′ and driveand driven pulley arrangement 1660 a and 1660 b, which allows forlateral translation of body 1654 and the components associatedtherewith, including Y-carriage 1652 and movable rack member 1656,container grasping member 1648. Carriage system 1650 includes guidemembers 1650 a,b, a drive mechanism 1660 that includes and is driven ina suitable manner such as a toothed belt 1660′ and drive and drivenpulley arrangement 1660 a and 1660 b and carriage follower 1654.Carriage follower 1654 supports Y-carriage 1652, which allows formovement normal to the longitudinal axis of X-carriage 1650 of containergrasping device 1648.

[0439] Guide members 1650 a,b are each an elongated guide that definesthe lateral translation movement direction of carriage follower 1654 andis secured within cabinet 1602. A suitable drive motor (not shown) isused to rotate drive pulley 1660 a. The drive motor can be an AC or DCmotor or a stepper or servo motor as desired. Suitable sensors can beemployed (not shown) to determine the position of carriage follower 1654which determines the lateral position of container grasping member 1648.

[0440] Carriage follower 1654 is composed of a frame 1662 having guideapertures 1664 a,b in which carriage guides 1650 a,b are disposed. Thus,X-carriage system 1650 provides lateral movement in the direction ofarrows AA as shown in FIG. 88. In this manner, carriage follower 1654and thus container grasping device 1648 and Y-carriage 1652 can belaterally translated as desired.

[0441] Container grasping device 1648 can be horizontally moved towardsand away-from X-carriage 1650 in the directions indicated by arrow BB inFIG. 88 by operation of a carriage follower mechanism 1666 that formspart of container grasping device 1648 and is guided by Y-carriageguides 1652 a,b. Y-carriage follower mechanism 1666 can be ahorizontally extending carriage system similar to that described withrespect to X-carriage system 1650 and can be controlled in a similarmanner. Alternatively, Y-carriage movement can be accomplished by anactuator, which could be an air cylinder, for example, not shown. Tograsp a container, suction cups are pressed against a surface of thecontainer and the vacuum is activated.

[0442] When container grasping device 1648 is in position adjacentcontainer magazine 1630 as shown in FIG. 89A, it is utilized to graspand retrieve a desired size of container from one of the apertures 1638a-d from container storage magazine 1630. For this purpose, containergrasping device 1648 includes a suction cup device 1668 which includesat least one suction cup 1670 and in the illustrated embodiment twosuction cups 1670 and 1672 typically arrayed to conform to the erectedcarton front wall and thus typically will be in substantially the sameplane for grasping a container having a surface to be grasped by bothsuction cups 1670 and 1672 in generally the same plane. Suction cupdevice 1668 also includes a vacuum source, a release valve and asuitable vacuum line (not shown) which connects suction cups 1670 and1672 to the vacuum source, which can be similar to that arrangement asillustrated in FIG. 30, for example. In operation, when suction cups1670 and/or 1672 engage a container or other member to be grasped, thevacuum source is activated to supply vacuum to suction cups 1670 and1672, such as to grasp and retain a container from one of apertures 1638a-d of container storage magazine 1630.

[0443] In a typical operation, container retrieving and grasping device1648 will be operated to position suction cups 1670 and 1672 adjacentand in operative contact with a container to be selected from containerstorage magazine 1630 as shown in FIG. 89A. Suction cups 1670 and 1672are at a desired height so that they engage a container contained at thefront of container storage magazine 1630. The vacuum source is activatedand container grasping device 1648 is moved away from magazine 1630 toremove a container from a desired one of apertures 1638 a-d of containerstorage magazine 1630 as shown in FIGS. 89A and 89B. Carriage system1652 can be activated to move container retrieving and grasping device1648 laterally away from magazine 1630, which causes the selectedcontainer to be pulled from the selected magazine, which in this case ismagazine 1630 a. Guides 1644 a maintain container C in proper lateralposition as container C is pulled through aperture 1638 a in thedirection of arrow EE. Restraining member 1642 a restrains the rear wallof container C as it is pulled through aperture 1638 a and a jet ofcompressed air from air nozzle 1674 facilitates the separation of thefront and rear sidewalls of container C while at the same time thebottom of container C is urged up as it traverses inclined ramp 1653 ato cause container C to be erected. Such lateral movement can becontrolled by properly positioned sensors as known in the art. Forexample, one sensor each can define the position to retrieve a containerfrom apertures 1638 a-d, respectively. Another sensor can be positionedto define the home or fully retracted location of container graspingdevice 1648 after erection of the container that has been retrieved fromone of apertures 1638 a-d of container storage magazine 1630. Aftererecting the container, X-carriage 1650 moves the erected container C inthe direction of arrow FF to elevator 1628 and releases the erectedcontainer C by releasing the vacuum to suction cups 1670 and 1672,depositing it in receptacle 1628′ of elevator 1628 as shown in FIG. 89C,where container C is then lowered in the direction of arrow GG byelevator 1628 to a suitable position for container filling device 1614.The vacuum applied to suction cups 1670 and 1672 can be released byoperation of a release valve (not shown) or other device which permitssuction cups 1670 and 1672 to disengage and release the container thathad been grasped.

[0444] For example, a container bottom urging device similar tocontainer bottom urging device 766 could be used in place of inclinedramps 1653 a-d. In addition, the opposed sidewalls of the French frycontainer could be separated by a device such as container handlingsystem 610, which includes suction devices that attach to each side ofan unerected container after the container is removed from a containermagazine. For example, see FIGS. 40-42, for example. As a non-limitingexample, such a device could be located in front of a portion ofcontainer magazine 1630, for example, using container grasping device onone side of the container and a device such as container grasping device764 (shown in FIGS. 38 and 40, for example) on the other side of thecontainer to be erected.

[0445] Elevator 1628 may be constructed in any suitable manner. In theillustrated embodiment, elevator 1628 is a rodless cylinder that carriesa receptacle 1628′ which is well-shaped and suitable to contain anerected French fry container. Receptacle 1628′ is movable by elevator1628 from a first or raised position as illustrated in FIG. 89C adjacentor otherwise in a suitable position for container handling system 1622to a second or lowered position suitable to be handled by containerfilling device 1614 as partially shown in FIG. 89D.

[0446] As shown in FIG. 89D, scoop or funnel 1710 of container fillingdevice 1614 is inserted into container C, in the direction of arrow HHand grasps container C from receptacle 1628′ when receptacle 1628′ is inthe second or lowered position. Container filling device 1614 operatesto fill erected French fry containers that typically will be individualportion-sized French fry containers. Container filling device 1614 iscomposed of a multi-link mechanical arm 1616 that includes an end-of-armtool 1626, that includes scoop or funnel 1710, is capable of grasping aFrench fry container, moving to an appropriate position via carriage1618 and mechanical arm 1616 for scooping it into French fries FFcontained in holding bin 1612 in the direction of arrow NN (see FIG.89E) to fill French fry container C with French fries, relatively gentlyshaking the filled French fry container to seat the French fries in thecontainer and to dislodge any loosely contained French fries whilecontainer C is slightly inclined, thereafter moving container C to anupright position as indicated by arrows II and JJ (see FIG. 89F) bymoving second link 1692 and third link 1694 in the direction of arrowsKK and LL, respectively, as shown in FIG. 89H. Thereafter, arm 1616deposits and releases the filled French fry container at drop-offlocation 1620 as shown in FIG. 891 by moving container C in a generallydownward direction indicated by arrow PP, which location typically willinclude a holding structure configured to receive and contain the filledFrench fry containers from where they can be picked up by a humanoperator, for example.

[0447] Mechanical arm 1616 can be configured and operated to generallymimic the arm, wrist and hand action of a human operator in scoopingFrench fries into a French fry container and to shake the filled Frenchfry container to remove loosely contained French fries and to morefirmly seat French fries contained in the container.

[0448] In the illustrated embodiment, which is best shown in FIGS. 74,76, 89G-H and 90A-F, multi-link mechanical arm 1616 includes first,second and third links 1690,1692 and 1694, respectively, and anend-of-arm tool 1626 that is carried by third link 1694.

[0449] First link 1690 is pivotally connected to a mast 1696 via a pivotconnection 1698. Mast 1696 is secured to a carriage follower 1712 andcan be horizontally translated via carriage 1618. First link 1690 isconnected to second link 1692 at adjacent ends thereof via pivotconnection 1700 allowing second link 1692 to pivot relative to firstlink 1690. Adjacent an opposite end of second link 1692 to pivotconnection 1700 is connected third link 1694 to second link 1692 via athird pivot connection 1702.

[0450] End-of-arm tool 1626 is rigidly connected to third link 1694 by asuitable structure, such as welding or use of a threaded fastener, forexample. End-of-arm tool 1626 is configured as a French fry scoop orfunnel and is configured to facilitate the filling of French frycontainers which are held by end-of-arm tool 1626. End-of-arm tool 1626includes a French fry container grasping mechanism 1704. French frycontainer grasping mechanism 1704 is composed of a movable finger 1706and an actuator 1708 for movable finger 1706. Thus, when French fryscoop or funnel 1710 of end-of-arm tool 1626 is inserted into an erectedFrench fry container C as illustrated in FIG. 90D, actuator 1708operates to move movable finger 1706 to a closed position in whichmovable finger 1706 moves in the direction of arrow MM and clamps therear sidewall C′ of container C against French fry scoop 1710 therebysecuring container C in a fixed position at the outlet end of French fryscoop or funnel 1710. In this manner, mechanical arm 1616 can grasp acontainer C that has been placed in receptacle 1628′ of elevator 1628when in the second or lowered position, as illustrated in FIGS. 89D and90B.

[0451] Carriage 1618 for mechanical arm 1616 allows mechanical arm 1616to be laterally moved in the direction of arrow AA to desired locationsdepending on the task that is to be performed by mechanical arm 1616 asindicated in FIG. 90A, for example. Thus, carriage 1618 allowsend-of-arm tool 1626 to be laterally moved from an erected carton pickuplocation as illustrated in FIG. 90B to a French fry container fillinglocation where end-of-arm tool 1626 can be scooped through a quantity ofFrench fries contained in holding bin 1612 to thereby cause the erectedFrench fry container to be filled with French fries and to transfer thefilled French fry container to drop-off location and holding structure1620, where mechanical arm 1616 releases the filled French fry containerfor subsequent pickup by a human operator, for example.

[0452] Carriage 1618 includes a carriage guide 1618′ and a carriagefollower 1712 that traverses carriage 1618 and to which is mounted mast1696. Lateral translation along carriage 1618 of carriage follower 1712is accomplished by any suitable structure and may be by means of arodless air cylinder. Carriages 1650, 1652 and 1608′ can also be drivenby a rodless cylinder or any other suitable device.

[0453] Mechanical arm 1616 is composed of three links that are pivotallyinterconnected permitting movement so that each of the links arepivotable in parallel planes which in the illustrated embodiment areeach in a vertical direction. Pivotable movement of each link isaccomplished by a suitable actuator 1714, 1716 and 1718, one for each ofpivot connections 1698, 1700 and 1702, respectively. Actuators 1714,1716 and 1718 can be any suitable type of actuator to provide thedesired rotational movement including, such as, an electric motor, anair driven motor and a stepper motor, for example. Actuator 1714 causesrotation of first link 1690 relative to mast 1696 about pivot connection1698. Actuator 1716 causes rotation of second link 1692 in a verticalplane about pivot connection 1700 and actuator 1718 causes rotation ofthird link 1694 in a vertical plane about pivot connection 1702. Variousmovements of mechanical arm 1616 of first, second and third links1690-1694, respectively, are illustrated in FIGS. 76, 89E-H and 90A-F,for example.

[0454] In one illustrated embodiment, filled French fry collectiondrop-off location and holding structure 1620 is configured as aninclined holding rack 1730 as illustrated in FIG. 891, for example.Inclined holding rack 1730 includes a plurality of separate lanes,namely, first lane 1732, second lane 1734 and third lane 1736, forreceiving small, medium and large size filled containers of Frenchfries, as illustrated in FIG. 891.

[0455] Alternatively, a carousel-type structure may be provided, namely,holding carousel 1738, as illustrated in FIG. 91. Holding carousel 1738is composed of a plurality of radially extending individual compartments1740 a-c, the number of compartments being limited by the size ofholding carousel 1738 and the desired size for each compartment. Asuitable drive mechanism 1742, which may be an electric motor isprovided for causing rotation of holding carousel 1738.

The Control System and Method

[0456] In one embodiment, the System Master Controller comprises aServer (PC), a router/hub, and a touch-screen monitor (user interface).The Master can utilize existing technology to integrate, to manage, tocontrol, and to coordinate information flow of and through the varioussubsystems for overall system operation. The network technology is fullycompliant with the latest version of the industry's NAFEM Protocol.

Control System Features

[0457] Referring to FIGS. 69-73, the primary functions of the ControlSystem are to receive order information from the POS and to connect andcoordinate all operating subsystem controllers with the MasterController so that operational commands and functional information canbe communicated and displayed. The result is that all the dispensing,fry and packaging modules function as one integrated fried foodsproduction system.

[0458] In one embodiment, the Control System is event and demand driven.That is, nothing happens unless a functional component or subsystemreceives a command signal to initiate the action. In a normal operationmode, the POS will provide virtually all of the system order demands.These can take the form of a string of two-bit Order Events. Typicallythis will be a quantity and an item (for example, 2 each regular sizefries). The product description can consist of both the food item andits portion size, treated as one bit of information.

[0459] The Control System information can be categorized into OrderEvents, Inbound Events, and Outbound Events. The Order Events come fromprimarily the POS system, the historical kitchen management system (KMS)data, or the touch-screen Monitor if a manager wants to override theautomatic ordering. KMS is a database of information of, for example,the sales rate of various products versus day and time. The Order Eventsdictate and demand the operation and performance of the automationcontrol system for production. The Inbound Events information includesmessages generated by subsystem controllers other than the POS or KMS.The Outbound Events include typical command messages issued by theMaster Controller specifying functions to be performed by individualsubsystem controllers.

[0460] In one embodiment, the Master Controller is configured to monitorperiodically or continuously the network for events to occur. Once anevent takes place and a signal is sent on the network, the MasterController identifies the source of the signal, then compares it to theprogrammed schedule of events within its memory, and reactsappropriately, either sending out a new command, showing a display,storing information in memory, or all of the above.

[0461] An important source of data for the Control System can be theKitchen Management System (KMS). The KMS is a historical database ofoperational information. This information can be used to set theworkstation configuration, process settings, inventory levels, and set alevel of production in advance of actual customer demand orders. Thisinterface can be a two-way connection, so that all operational data fromthe Fried Foods Workstation can be received and stored in the KMS and/orthe Control System, or evaluated, adjusted, and reentered to “fine-tune”the process on a continuing basis.

[0462] Generally, the Control System can comprise two loops, shown inFIG. 70. The primary loop is the “Order-to-Package” loop, whereby theMaster Control takes an Order Event input from the POS and directs theappropriate Packaging Module subsystem to package and deliver anappropriate portion of product. A secondary loop is the “BufferReplacement” loop, where the Master Controller receives an Inbound Eventsignal from the Packaging Module that its buffer inventory ofready-to-package fried product is low and additional product must bedispensed and fried. As currently specified, all products other thansalted French fries typically can have a default buffer inventory ofzero, meaning that an order for that (other) product will immediatelyinitiate a full dispense-fry-package (if packaged by the System)production routine.

[0463] In accordance with one aspect of this embodiment of the ControlSystem, the Fryer Module vat operation is not directly controlled by theproduction demand cycle. Each fry vat of the fry module will operatecontinuously and on a pre-set uniform operating cycle. Frozen product isdropped into the fry module when additional inventory is called for. Theproduct is fried according to the pre-set cooking cycle and then isdumped into the Packaging (or Protein) Module receiving apron. None ofthe cooking cycle is affected by order demands, or inventory conditions.In one embodiment, the Control System can vary the time betweenincremental rotation and speed of rotation of fry wheel 410 toaccommodate for varying conditions, such as the level of cooking oil inthe fry vat. The level of cooking oil can vary as a result of the amountof product that is being fried in a particular fry vat, since productpresent in the fry vat displaces cooking oil, thereby raising the levelof cooking oil in the fry vat particularly since the product is heldbelow the cooking oil surface during a cooking cycle. Preferably, toensure the workstation reliability and system uptime, extensive controlredundancy can be provided. As a result, the control subsystems for eachFryer Module vat and each Dispensing Module chute are designed andconstructed as individual units that operate even if one or moresubsystem fails.

[0464] Additionally, the control of the Dispensing Module freezerenvironment and operation can be an independent subsystem.

[0465] Preferably, the Control System includes the capability to operateall modules individually. This allows the operator to disconnect andremove a module from the network and operate the remaining modules in asemi-automatic method, manually performing some of the operations.Preferably, there are controls on each module that permit an operator tooperate that module's functions locally.

[0466] Orders for product are preferably processed sequentially as theyare received, although the specific products within a customer order maybe arranged in a logical manner as desired. The Monitor will display allproducts being processed by the workstation from the time the order isreceived until it is removed from the workstation. The status of eachproduct that is ordered can be tracked in its various stages including,for example, on order, packaged and ready to pick up, ready to manuallypackage, and held too long.

[0467] Preferably, products in the process of being fried can also betracked, and cooking times for each basket in each wheel will count downto when product is ready to package.

Master Controller

[0468] In one embodiment, the Master Controller 110 hardware maysuitably comprise, or equivalent:

[0469] Intel Pentium III (or higher) with 1.0 GHz (or higher) CPU

[0470] Ethernet network interface and hub

[0471] 256 MB (or more) system RAM

[0472] 20 GB (or more) hard disk drive

[0473] Touch-Screen Monitor Interface

[0474] Plug and Play Touch-Screen Monitor

[0475] SCK Gateway (Ethernet)

[0476] Interconnect cabling (as needed)

[0477] Optional Keyboard and pointing device (mouse) for installationand maintenance purposes

[0478] Typical operating system software requirements are:

[0479] Windows 2000 professional (or server) SP4 or higher

[0480] A suitable Database Server, such as Fast SCK Version 3.0 (orhigher) from Fast, Inc. of Stratford, Conn.

[0481] Fast SCK Version 3.0 (or higher) Utility Applications (SCKEditor, SCK Engine, SCK Events, and SCK Site Editor) from Fast, Inc.

[0482] The Subsystem Interface Modules provide the functionality tocommunicate specific control events (information) conditions, and/orcommands to and from the Master Controller. These modules typically canbe incorporated into the circuitry of controller boards. In cases wherethe network needs to interface with a control subsystem (such as PLCs,for example), appropriate imbedded memory interface (input-output)circuit cards known in the art can be utilized. All of the foregoinghardware and software or equivalent is readily available or can beproduced by those skilled in the art.

Fryer Controller

[0483] The frying of the frozen product is controlled by a combinationof cooking oil temperature and the time the frozen product is immersedin the cooking oil. Frying is accomplished by moving the frozen productthrough the heated cooking oil by a rotating fry wheel. As previouslydescribed, a programmable stepper or other motor can provide the desiredprecisely controlled movement of the fry wheel.

[0484] The following Table I lists typical control parameters andseveral optional parameters that can be used, if desired. TABLE I FryerModule Control Signals (One set for each of 4 Product Lanes) DescriptionInput Output Op. Adj. Set Temperature X X Actual Temperature X “Ready”Band Width X Temperature Offset X C or F X X Probe #1 X Heater Relay #1X Total Cook Time X X Jog Speed X Jiggle Time X Cleaner Level X Oil FillX Cleaner Fill X Probe #2 X Heater Relay #2 X Flex Time X

[0485]FIG. 71 depicts a typical motor/fry wheel/basket cycle. Virtuallyevery parameter can be fixed or adjustable as desired. For example,during one typical cycle, which may be for a preset period of time thatis one-quarter of the cooking time for food contained in a compartment,fry wheel 410 is rotated clockwise 4520 in the direction of arrow K ofFIG. 13. After some period of time after the 45° incremental rotation, abasket shaking simulation of back and forth rotation occurs over aperiod of about two seconds. After a 0 to 10-second delay, anotherbasket shaking simulation occurs. Thereafter, a period of time (“BasketLoad Window’) is available for loading another compartment, such ascompartment 436 with a charge of French fries or other food to be fried.Thereafter, a “no load zone” or relatively short period of time towardsthe end of the cycle is set aside just prior to another 45° fry wheel410 rotation in the direction of arrow K, which commences another cycle.During each cycle, three “home routines” can be employed, one after eachrotation of fry wheel 410 to accurately locate fry wheel 410 so that itis properly positioned with the upper end of compartment bottom 510 a ofone of fry wheel 410 compartments adjacent discharge 498 and another ofthe compartments properly aligned to receive a charge of French fries orother food to be fried, such as from food dispensing device 200.

[0486] To ensure proper operation of the basket/fry wheel, includingpositioning the unit precisely for smooth loading and completeunloading, the basket/fry wheel position must be constantlysynchronized. To do this, a “homing” sensor circuit can be utilized thatresets the home position after every move of the wheel. This sensorpreferably is electromagnetic and is impervious to dirt and grease buildup and has no moving parts although any suitable sensor can be used.

Dispensing Controller

[0487] The Dispensing Module control system 114 separates functions bythe product delivery lane they support. In one embodiment, where thereare four delivery lanes, there are four control subsystems. Eachsubsystem controls a vibrating product conveyor, a portioning load cell,and a dump actuator. Additionally, there are optional moduleconfigurations that affect the controls design. If lanes 1, 2, and/or 3are configured with bulk food hoppers, a product level sensor can beprovided to alert operators to reload frozen product before the hopperis empty. If each of lanes 2, 3 and/or 4 is configured with an array ofcoil magazines for food items, the controls must sequentially switchpower to each of the motors in the lane to maintain a constant flow offrozen product.

[0488] Table II lists defined control signal parameters for each of theDispensing Module Lane controllers: TABLE II Dispensing Control Signals(One set for each of 4 Product Lanes) Description Input Output Load -Small Qty. X Load - Large Qty. X Load Coil A X Load Coil B X Load Coil CX Load Coil D X Load Coil E X Ready to Dump X Vibrator Frequency X BulkFill Level X Time Out X Overweight X Clean Out X

Freezer Controller

[0489] In addition to properly dispensing products into the FryerModule, subcontrol system 114 for dispensing device 200 or 1200 mustalso maintain a proper frozen environment for all products. Toaccomplish this, another controller subsystem can be provided. TableIIII lists the applicable control signal parameters for the freezersubsystem. A safety circuit interrupts all dispensing activity when theaisle door is opened. TABLE III Freezer Control Signals DescriptionInput Output Op. Adj. Set Temperature X X Actual Temperature X AisleDoor Open X

[0490] The separation of the Dispensing Module controls into these fivesubsystems, when there are five, makes for a convenient mechanicalarrangement in the base of the module, and allows for the requiredflexibility given the configuration options.

[0491] In one embodiment, for manual operation, four “dispense” buttonsare provided, one for each lane. One button would cause the release of apre-set portion of the frozen product for that lane. The controlspreferably should be located so the operator could by visual observationdetermine the appropriate fryer basket to make sure the productdispenses into the proper basket.

Packaging Controller

[0492] Packaging Controller 118 for the Packaging Module incorporatesseveral event signal generators for the control system to sense or read.The main Packaging Module or device 600 and 1600 elements are depictedin FIGS. 25-29 and FIGS. 86-90, respectively. In one embodiment, thePackaging Module or device control system includes two subsystems withinthe Packaging Module, the packaging subsystem and the heated foodstorage device 635 that can be used in place of packaging device 600 or1600

The Packaging Subsystem

[0493] The packaging control subsystem initially interfaces with thePackaging Module PLC and sends packaging device 600 or 1600 a signal tostart the sequential operation of packaging one of an appropriatelysized portion of French fries. The actions and reactions of all theelectromechanical devices (e.g., for device 600: container handlingsystem 610, dispensing member 606, overflow member 613, load cell 702and chute mechanism 608 and for device 1600: container handling system1622, elevator 1628, salting device 1606 and carriage 1606′, first andsecond gates 1608 and 1610, and container filling device 1614) can be,if desired, sequenced and controlled by the local on-board controller(i.e., PLC) and not Master Controller 110.

[0494] For device 600, once the container grasping device 764 sets thefilled package of fries on conveyor 614 and the receptacle load gate 926opens to allow receptacle 612 to move to the pick up area, a signal willbe sent back to Master Controller 110 indicating that the particularorder of fries is ready for pick up. Until that receptacle 612 moves tothe return gate 928 (located at the operator right front of thePackaging Module) and the gate permits receptacle 612 to move therepastafter receptacle 612 is empty, Master Controller 110 will believe (anddisplay) that the order of fries is waiting to be picked up. Preferably,the crew member will pick up fries from right to left to ensure that theorder sequence is followed and that the oldest fries are served first.

[0495] Because the number of receptacles 612 that can fit between gate926 and return gate 928 typically is limited, Master Controller 110intelligence preferably keeps track of how many orders of fries are inthe pick up cue. This allows audible/visual alerts to be triggered onthe Monitor to remind the crew that orders have been waiting. Also, evenif orders are picked out of sequence, the Master Controller willremember what was on an empty receptacle 612 and clear it when it passesreturn gate 928.

[0496] Preferably, the Master Controller is configured to remember thehold time of each packaged fry order. If the order has not been pickedup in time, the Monitor will alert the operator by audible/visual signalto “waste” that order.

[0497] For device 1600, once automated mechanical arm 1616 deposits afilled package of fries at drop-off location, Master Controller 110 willbelieve and display that the order is ready for pick-up from theparticular lane of rack 1730 or from a particular compartment of holdingcarousel 1738, the rotation of which can be controlled by MasterController 110.

The Secondary Loop

[0498] The remainder of control 118 for Packaging Module or device 600or 1600 functions address the secondary loop, “buffer inventoryreplacement.” Preferably, there are two typical system requirements forthe buffer inventory: (1) there must be a minimum amount of fries inmember 606 or chute mechanism 608 (for device 1600, in holding bin 1612and/or on chute 1604) to completely fill the next packaging order (thatis, enough French fries to make one portion of a given size given theparticular filling efficiencies of the filling device of packagingmodule 600 or 1600); and (2) the buffer inventory is low and needs to bereplenished.

[0499] For the first requirement, if there is insufficient bufferinventory to fill the package, chute mechanism 608 or mechanical arm1614 is disabled or held inactive and an error message alarm is sent.This condition should not happen, but the control intelligence preventspackaging device 600 or 1600 from under filling an order.

[0500] During normal operations, the level of fries in the bufferinventory will drop to a level where an inventory replenishment orderwill be initiated. In that event, Master Controller 110 can signaldispensing device 200 or 1200 to start its fill sequence. This processshould typically start soon enough that the replacement product can befried, salted, and added to the dispensing member 606 or to holding bin1612 or on inlet chute 1604 before the “out-of-product” condition isreached. The KMS data can be integrated into the Master Controlintelligence to help insure that there is replacement product in processbefore the actual need arises. This capability minimizes order deliverydelays while also preventing the dispensing member 606 or in holding bin1612 or inlet chute 1604 inventory growing beyond actual need.

[0501] The dispensing member 606 (or holding bin 1612 and/or inlet chute1604) inventory can be managed in a number of ways, as desired. Forexample, any of the following can be utilized and implemented by one ofordinary skill in the art: (a) direct sensors; (b) a load cell thatconstantly weighs the buffer inventory; and (c) a dynamic empiricalcalculation.

[0502] The dynamic empirical calculation embodiment may use the MasterController to constantly calculate how much product has been added todispensing member 606 (or holding bin 1612 and/or inlet chute 1604), andsubtract out the portion packaged, any bonus amount, waste, and a safetyfactor. This empirical total will then be compared to pre-set “reload”levels. The formula may also include how much product is in process. Inall cases, the buffer inventory level can be adjusted during the day toreflect actual sales levels.

[0503] The controls system design for all other (i.e., non-salted Frenchfries) products is that the same control process would be used, but thatthe “buffer inventory” for those products may be defaulted to zero. Thatis, an order for hash browns would immediately signal an“out-of-inventory” condition and launch an “inventory replacement”command to the dispensing device 200 or 1200. Later, if the need arises,controller intelligence would allow the operator to utilize some bufferinventory for these products.

[0504] Optionally, a provision can be made for unsalted French fries.Unsalted French fries would be handled like the non-French friesproducts. When an order for unsalted French fries is received, MasterController 110 will signal the Packaging Module to move diverter bar605. The next load of French fries coming from the Fryer Module willthen be diverted to a portion of chute 604 of packaging device 600 formanual packaging. The extra unsalted fries can be manually returned tochute 604.

[0505] An important feature of the automated system is to maintainproduct integrity. One facet of that is to dispose of product that hasexceeded its authorized holding time. Master Controller 110 willremember when each load of French fries came out of fry device 400. Themechanical design of packaging devices 600 and 1600 assures asubstantially “first in-first out” product movement. How long the“oldest” fries have been in dispensing member 606 is tracked by MasterController 110 or packaging device controller 118, as desired. Wheneverthe allowable holding time has been reached, Master Controller 110 willsignal the Packaging Module subsystem Controller 118 to start the bufferwaste cycle (or the packaging device Controller 118 can directly controlthis function). It is possible that some French fries in the buffer willnot have reached their limit, but through control parameter refinement,this can be minimized. Table IV lists the control signals for oneembodiment of the packaging control subsystem: TABLE IV PackagingControl Signals Description Input Output Op. Adj. Package #1 X Package#2 X Package #3 X Package #4 X Divert Fries X Produce #5 X Produce #6 XProduce #7 X Produce #8 X Produce #9 X Dump Buffer X Buffer Low X BufferFull X Receptacle Loaded X Receptacle Empty X Time out - System 610 XProduct #5-9 Picked X

Holding Controller

[0506] The other control subsystem is that dedicated to holding productat proper temperatures. Generally, a standard temperature controllerwith timer channels to manage all holding functions can be utilized, asis known in the art.

[0507] Table V lists the various control parameters for the holdingcontrol subsystem for food holding device 635: TABLE V Holding ControlSignals Description Input Output Op. Adj. Buffer Temp Set X X BufferTemp Act X Pick Up Temp Set X X Pick Up Temp Act X Apron Temp Set X XApron Temp Act X Holding Temp Set X X Holding Temp Act X Holding Time #1Start X Holding Time #1 End X Holding Time #2 Start X Holding Time #1End X

Touch-Screen Monitor

[0508] The Touch-Screen Monitor is the primary system user interface andcan be considered part of the Master Controller configuration. TheMonitor has four main functions: (1) display the status of fried foodsorders; (2) allow the operator to manually control the system; (3) alertthe operator to any needed manual intervention; and (4) allow theoperator to reconfigure the workstation and/or change the individualoperating parameters.

[0509] The Monitor display can be configured as desired. Preferably, themain display menu is simple, uncluttered and only presents the basicinformation needed to track ongoing order status. A sample Monitordisplay layout is shown in FIG. 72.

[0510] In the illustrated embodiment, products on order would appear ashorizontal rows of the appropriate product (type and portion size) icon,reading from the left edge of the screen. All products from a single POScustomer order would appear on a single line. As additional POS ordersare entered, the screen would refresh, moving the older orders down aline. Products on order, and not yet ready for pick up would appear asgold icons.

[0511] Across the bottom of the screen would appear the same number oflocations as there are packaging device 600 receptacles 612 in the pickup zone. As packages of fries are placed on receptacles 612 and thereceptacles 612 travel within the pick up zone, the appropriate iconwill disappear from the “on order” line and reappear as a green icon inthe spot where its receptacle is. When a package is removed from areceptacle and that receptacle passes return gate 928, the display iconwill disappear from the screen.

[0512] In one embodiment, should the “hold timer” for a packaged productexpire before it is picked up, its green icon will change color (i.e.,to red) and/or flash. In another embodiment, an audible alarm can beprovided as well, indicating clearly that this product should be wasted.

[0513] Across the top of the screen is a line of control “buttons.”There can be one for each product (again, type and portion size). Thesystem is programmed so that touching the button on the screen willenter an order for one each of that product. There is also a screenbutton at the upper right corner of the screen that enables the operatorto change the screen display to the “Settings” screen.

[0514] The “Settings” screen layout is depicted in FIG. 73. From thisscreen, the operator may now configure all the operating settings forthe product to be run in each product lane. The individual settings mayinclude dispensing load size(s), fry vat temperature, cooking cycletime, buffer inventory level, packaging device Module heater setting,and other settings as desired. In this embodiment, all settings for aparticular product are linked to that product. The operator can merelyscroll in each product lane and signify the product that will be run init. Master Controller 110 will then set all operating parameters forthat product. If it is necessary to check or adjust an individualcontrol setting (such as cook time), the operator can scroll through theitems in the “settings” box for that lane and product. Then, using the“up” and “down” keys, readjust the setting and press the “enter” key toreset.

[0515] If required, a secure “manager only screen” can be configured toallow someone to adjust and/or reset selected operating parameters.Access to this screen and these settings would require some type ofpassword to prevent any non-authorized store employee from changingbasic system parameters.

[0516] Operator alert messages or alarms (e.g., bulk product low—refillnow: “bridging/time out”—clear lane 2; etc.) will appear as an “errormessage box” in the center of the screen, along with some type ofaudible alarm.

[0517] While the invention has been described with respect to certainpreferred embodiments, as will be appreciated by those skilled in theart, it is to be understood that the invention is capable of numerouschanges, modifications and rearrangements and such changes,modifications and rearrangements are intended to be covered by thefollowing claims.

1. An automated dispensing device for dispensing a quantity of food tobe cooked comprising: a freezer; a storage container located in thefreezer for containing food to be dispensed; means for dispensing apredetermined quantity of food from the storage container into asecondary container, said means for dispensing located in the freezer;and means for dispensing the quantity of food from the secondarycontainer to a location outside of the freezer.
 2. The automateddispensing device of claim 1 wherein said secondary container comprisesat least a partially open bottom, the secondary container being movablelaterally between a filling position located within the freezer and adispensing position for dispensing food through the container openbottom and out of the freezer.
 3. The automated dispensing device ofclaim 2 wherein said means for dispensing a predetermined quantitycomprises a vibratory conveyor located below said storage container. 4.The automated dispensing device of claim 3 wherein said means fordispensing a predetermined quantity of food further comprises a devicefor determining the quantity of food located in the secondary containerand means for terminating the operation of said means for dispensingwhen a predetermined quantity of food is sensed in the secondarycontainer.
 5. The automated dispensing device of claim 4 wherein thedevice for determining the quantity comprises a load cell.
 6. Theautomated dispensing device of claim 4 wherein the means for dispensingfrom the secondary container comprises a device for moving the secondarycontainer laterally sufficiently to the dispensing position so that foodcontained therein is dispensed.
 7. The automated dispensing device ofclaim 6 further comprising a door that is located over an opening in thefreezer compartment in position relative to the secondary container sothat when the secondary container is moved laterally to the dispensingposition, the food in the secondary container exits the freezercompartment through the open bottom and through said freezer compartmentopening.
 8. The automated dispensing device of claim 2 wherein saidmeans for dispensing a predetermined quantity of food comprises a foodmagazine capable of dispensing individual pieces of food on apiece-by-piece basis.
 9. The automated dispensing device of claim 8wherein said magazine comprises dual rotatable spiral flights, saidspiral flights having a spacing to allow a food item selected from thegroup consisting of chicken patty, filet of fish, single serving unitaryhash brown and single serving pie to be placed therebetween.
 10. Theautomated dispensing device of claim 3 wherein said vibratory conveyorhas a serpentine food travel pathway.
 11. The automated dispensingdevice of claim 8 wherein said means for dispensing further comprises avibratory conveyor disposed below said magazine.
 12. The automateddispensing device of claim 3 further comprising said vibrating conveyorincludes a bottom portion having a plurality of spaced apart holes lessthan about 0.25 inches in diameter.
 13. The automated dispensing deviceof claim 3 further comprising a generally vertically extendingdeclumping member having a portion located above a bottom portion of theconveyor.
 14. The automated dispensing device of claim 1 wherein saidsecondary container comprises a platform and a container with at least apartially open bottom and located above the platform, the platform andthe container being movable relative to each other between first andsecond positions, and wherein in the first position the platform isadjacent the open bottom and prevents food from being dispensed from thecontainer and when in the second position food is free to fall throughthe open bottom of the container.
 15. The automated dispensing device ofclaim 2 wherein said means for dispensing a predetermined quantity offood further comprises a device for determining the quantity of foodlocated in the secondary container and means for terminating theoperation of said means for dispensing when a predetermined quantity offood is sensed in the secondary container.
 16. The automated dispensingdevice of claim 15 wherein the device for determining the quantitycomprises a load cell.
 17. A tray for vibratory conveying food articlesfrom a hopper comprising: a tray body, a food inlet portion and a foodoutlet portion, the food inlet including an upwardly extending dividingmember for dividing the tray into at least two food inlet conveyorpassageways, the inlet conveyor passageways merging into a single foodpassageway that extends to the food outlet portion.
 18. The tray ofclaim 17 wherein said single food passageway is non-linear.
 19. The trayof claim 18 wherein the single food passageway has a zigzagconfiguration.
 20. The tray of claim 18 wherein the single foodpassageway has a serpentine configuration.
 21. The tray of claim 17wherein the dividing member is saddle-shaped.
 22. The tray of claim 17wherein the single food passageway causes food the size of chickennuggets to be conveyed in a single file arrangement.
 23. A method ofdispensing a quantity of food to be cooked comprising: storing fooditems in a storage container; dispensing food items from the storagecontainer to a conveyor; conveying the food items on the conveyor to asecondary container having at least a partially open bottom with a floormember adjacent the open bottom; monitoring the amount of food itemsdelivered to the secondary container; terminating delivery of the fooditems to the secondary container when a desired amount of food items aredetermined to be present in the secondary container as determined bysaid monitoring; dispensing the food items from the secondary containerand through the open bottom of the container by relative movement of thefloor member to the open bottom of the container.
 24. The method ofclaim 18 wherein said conveying comprises vibratory conveying.
 25. Themethod of claim 23 wherein said dispensing comprises lateral movement ofthe secondary container relative to the floor member that remainsstationary.
 26. A device for the automated frying of foods comprising:(a) a fry vat for containing and heating cooking oil; (b) at least onecircular fry wheel having at least a generally circular perimeter and aplurality of compartments each having an opening towards the perimeter,the fry wheel mounted for rotational movement relative to the radialaxis of the wheel which radial axis is disposed above the normaloperating level of the frying oil in the fry vat; (c) a drive mechanismfor rotating the fry wheel; and (d) an overflow passageway having aninlet that is located above the normal operating level of the frying oilin the fry vat.
 27. The device of claim 26 further comprising a controlsystem for causing the drive mechanism to periodically rotate the frywheel back and forth through a relatively small amount of rotation tosimulate shaking of a fry basket.
 28. The device of claim 26 furthercomprising a foam deck adjacent a side of the fry vat and having a decksurface located above the normal operating level of frying oil in thefry vat, said overflow passageway comprising an elongated slot in thefoam deck.
 29. The device of claim 26 further comprising a food inletfor supplying a quantity of food to be fried into the compartments andlocated adjacent the overflow passageway.
 30. The device of claim 28further comprising a food inlet for supplying a quantity of food to befried into the compartments and located adjacent the foam deck.
 31. Thedevice of claim 30 wherein the food inlet comprises an inlet slidedisposed to direct food deposited on said inlet slide into one of thecompartments of the fry wheel.
 32. An automated method of frying foodcomprising: (a) placing food to be fried in a fry wheel compartment of afry wheel having at least a generally circular perimeter and a pluralityof compartments each having an opening towards the perimeter, the frywheel mounted for rotational movement relative to the radial axis of thewheel which radial axis is disposed above the normal operating level ofthe frying oil in a fry vat having heated cooking oil therein; (b)providing an overflow passageway having an inlet that is located abovethe normal operating level of the frying oil in the fry vat; (c)collecting in the overflow passageway at least some of thewater-containing foam when the food to be fried placed in the fry wheelcontacts the frying oil; and (d) rotating the fry wheel so that thecompartment containing the food travels submerged in the heated cookingoil.
 33. The method of claim 32 further comprising periodically rotatingthe fry wheel back and forth through a relatively small amount ofrotation to simulate shaking of a fry basket while the food is submergedin the cooking oil.
 34. The method of claim 33 wherein the periodicrotation in one direction is of a larger angle of rotation than therotation in the other direction.
 35. The method of claim 34 wherein therotating of paragraph (d) of claim 32 comprises rotating the fry wheelin one direction to cause food deposited into one of the compartments totravel through the cooking oil in the fry vat over a period of time tofry the food and out of the cooking oil for subsequent discharge of thefood from the compartment.
 36. An automated device for packaging cookedFrench fries into an individual portion-sized French fry containercomprising: a mechanical arm having an end-of-arm tool capable ofpicking up and grasping an erected individual portion-sized French frycarton from an erected carton pick-up location, and scooping the erectedcarton while held by the end-of-arm tool into a quantity of cookedFrench fries located at a filling location to fill the French fry cartonand depositing the filled French fry carton at a drop-off locationspaced from the filling location.
 37. The automated device of claim 36further comprising a French fry holding bin for holding a bulk quantityof French fries at the filling location and a French fry inlet chute forreceiving a bulk amount of French fries.
 38. The automated device ofclaim 36 further comprising means for vibrating the French fry inletchute.
 39. The automated device of claim 38 further comprising means forretaining French fries on the French fry chute.
 40. The automated deviceof claim 39 further comprising means for applying seasoning to Frenchfries contained on the inlet chute.
 41. The automated device of claim 39wherein the means for retaining comprises a plurality of verticallyreciprocable fingers movable between an extended position for retainingFrench fries on the inlet chute and a retracted position for permittingFrench fries to travel down at least a portion of the chute.
 42. Theautomated device of claim 40 further comprising a salter carriage formoving the means for salting horizontally across the inlet chute. 43.The automated device of claim 36 further comprising a movable gatelocated between the discharge end of the inlet chute and the holding binand movable between a raised position for retaining French fries on theinlet chute and a lowered position for permitting French fries to travelfrom the inlet chute to the holding bin.
 44. The automated device ofclaim 43 wherein said movable gate comprises a plurality of spaced apartfingers reciprocable in up and down directions to restrain French friesfrom sliding down the inlet chute when in an up position and fordeclumping French fries when the fingers are reciprocated up and downwhen French fries are traveling past the reciprocating fingers.
 45. Theautomated device of claim 37 further comprising a sensing deviceassociated with the French fry holding bin for determining whether adesired quantity of French fries are contained in the French fry holdingbin.
 46. The automated device of claim 45 wherein the sensing device isa weighing device.
 47. The automated device of claim 36 furthercomprising a French fry carton storage and erection device.
 48. Theautomated device of claim 47 wherein the French fry carton storage anderection device comprises an automated, unerected French fry cartonretrieving device for retrieving and grasping an unerected individualportion-sized French fry container.
 49. The automated device of claim 48wherein said automated retrieving device comprises a grasping member forselectively grasping and releasing the French fry container.
 50. Theautomated device of claim 49 wherein the automated retrieving devicefurther comprises structure for generally horizontally linearly movingsaid movable member in two generally horizontal dimensions.
 51. Theautomated device of claim 50 wherein said structure for linearly movingcomprises a carriage.
 52. The automated device of claim 50 wherein saidstructure for linearly moving comprises a carriage for each of saidhorizontal dimensions.
 53. The automated device of claim 48 furthercomprising a magazine for holding a plurality of the individualportion-sized French fry containers in an unerected state.
 54. Theautomated device of claim 48 further comprising a magazine for holding aplurality of segregated groups of individual portion-sized unerectedFrench fry containers, each group in the plurality being of a differentsize container.
 55. The automated device of claim 54 wherein themagazine holds each group of unerected containers in a horizontal stack.56. The automated device of claim 55 wherein said container retrievingdevice is positionable to retrieve containers from the front of eachstack.
 57. The automated device of claim 49 wherein said grasping membercomprises a suction device for grasping and releasing the French frycontainer.
 58. The automated device of claim 57 wherein said suctiondevice comprises a suction cup located on the grasping member that iscapable of said grasping and releasing by applying and releasing avacuum, respectively.
 59. The automated device of claim 58 wherein saidsuction device comprises two suction cups that are disposed adjacenteach other on the grasping member.
 60. The automated device of claim 49wherein said retrieving device is capable of grasping and releasing aFrench fry container on one side and further comprising means forerecting the unerected French fry container.
 61. The automated device ofclaim 60 wherein the container has a bottom and further comprisingurging means for urging the container to an erected position and forurging the container bottom upwardly relative to the sides of thecontainer when the retrieving device grasps the container and retrievesthe container from the stack.
 62. The automated device of claim 61wherein said urging means comprises an inclined ramp.
 63. The automateddevice of claim 62 further comprising means for applying a stream ofcompressed air into the top end of the container and towards the bottomof the container.
 64. The automated device of claim 61 furthercomprising an elevator for moving an erected French fry container from afirst location proximate said retrieving device to a second location.65. The automated device of claim 64 wherein the elevator comprises arodless cylinder and a receptacle for holding an erected French frycontainer and said receptacle being movable between said first andsecond locations by said rodless cylinder.
 66. The automated device ofclaim 65 wherein said second location is proximate said mechanical armso that a French fry container in said second position can be grasped bysaid end-of-arm tool.
 67. The automated device of claim 66 wherein saidmechanical arm is mounted to a carriage for providing lateral movementof said mechanical arm.
 68. The automated device of claim 67 wherein themechanical arm further comprises structure for selectively andindependently moving the end-of-arm tool through a generally verticalcompound arc.
 69. The automated device of claim 68 wherein themechanical arm further comprises structure for selectively moving theend-of-arm tool linearly up and down.
 70. The automated device of claim36 wherein said end-of-arm tool comprises a French fry scoop.
 71. Theautomated device of claim 70 wherein said end-of-arm tool furthercomprises a gripping mechanism actuable between clamping andnon-clamping positions wherein the gripping mechanism can grasp a Frenchfry container when in the clamping position and release the previouslygrasped French fry container when the gripping mechanism is in thenon-clamping position.
 72. The automated device of claim 71 wherein saidgripping mechanism comprises a finger.
 73. The automated device of claim72 further comprising an actuator device for moving said finger betweenclamping and non-clamping positions.
 74. The automated device of claim72 wherein the gripping mechanism clamps an upper end of the French frycontainer between the finger and the French fry scoop.
 75. The automateddevice of claim 70 wherein said mechanical arm comprises a plurality ofpivotable links connected in series.
 76. The automated device of claim75 wherein said mechanical arm comprises at least two pivotable links.77. The automated device of claim 75 wherein said mechanical armcomprises three pivotable links.
 78. The automated device of claim 77wherein the links are each pivotable in parallel planes.
 79. Theautomated device of claim 77 wherein the links comprise first, secondand third links, the first link connected to a generally horizontallymovable carriage, the third link connected to the end-of-arm tool andthe second link connected to the first and third links.
 80. Theautomated device of claim 79 wherein the connection of each of saidlinks to another link comprises a pivot connection.
 81. The automateddevice of claim 80 further comprising an actuator for each pivotconnection for pivoting the respective one of said links about the pivotconnection which connects that link to another of said links.
 82. Theautomated device of claim 36 further comprising a structure forcontaining a plurality of French fry cartons filled with French friesand at least a portion of the structure in communication with saiddrop-off location.
 83. The automated device of claim 82 wherein thestructure is a stationary rack that is inclined in a direction away fromsaid mechanical arm.
 84. The automated device of claim 82 wherein saidstructure comprises a rotatable carousel.
 85. The automated device ofclaim 36 wherein said mechanical arm is configured to mimic the motionof a person's arm, wrist and hand action in scooping French fries into aFrench fry container while grasping the French fry container in one handand moving the French fry container in a vertical arc, and thereafter,moving the French fry container to a generally upright position andshaking it sufficiently to cause loosely contained French fries to fallfrom the container.
 86. An automated method of packaging cooked Frenchfries in an individual portion-sized French fry container comprising:delivering with a mechanical device cooked French fries to a French fryholding bin; mechanically scooping with a mechanical device an openFrench fry container into the cooked French fries in the holding bin tofill the French fry container with French fries; and mechanicallydepositing the filled French fry container at a drop-off location. 87.The method of claim 86 wherein said delivering comprises receiving theFrench fries on an inlet chute before the French fries enter the Frenchfry holding bin.
 88. The method of claim 86 further comprising applyingseasoning to French fries while on the inlet chute.
 89. The method ofclaim 87 wherein said delivering comprises vibrating the inlet chute andusing gravity to cause the French fries to travel into the holding bin.90. The method of claim 87 further comprising moving a first gate forthe inlet chute to a position that restrains the French fries fromtraveling down the chute and applying seasoning to the French frieswhile so restrained.
 91. The method of claim 86 further comprisingmechanically shaking the filled individual portion French fry containerprior to said depositing.
 92. The method of claim 91 wherein saidshaking comprises back and forth movement through an arc of said filledindividual portion French fry container in a generally vertical axis.93. The method of claim 90 further comprising further restraining theFrench fries from exiting said inlet chute at a location downstream ofsaid gate after passing the first gate.
 94. The method of claim 93wherein said further restraining is performed by a second gatedownstream of the first gate.
 95. The method of claim 94, furthercomprising moving the second gate to a position that does not restrainthe French fries so that the French fries are free to travel into theholding bin.
 96. The method of claim 86 further comprising holding theindividual portion French fry container with a mechanical arm of themechanical device while performing said scooping.
 97. The method ofclaim 96 further comprising shaking the individual French fry containerby movement of said mechanical arm after said scooping.
 98. The methodof claim 97 wherein said shaking is performed by up and down verticalmovement of said mechanical arm.
 99. The method of claim 86 furthercomprising mechanically obtaining an unerected individual portion Frenchfry container to be filled from a stack of unerected individual portionFrench fry containers.
 100. The method of claim 99 further comprisingmechanically erecting the unerected individual portion container priorto said scooping.
 101. The method of claim 100 further comprising,before said obtaining, selecting and holding with the mechanical devicean individual portion-sized container of a desired size from a pluralityof different sizes of individual portion-sized containers that can beselected and held by said automated device.
 102. A method of erecting acollapsed individual portion-sized French fry type container of the typehaving opposed sidewalls connected by a collapsible container bottom,comprising: grasping the unerected French fry container, pulling thecontainer against a restraining member; mechanically dragging the bottomof the container so that it traverses up an inclined ramp to urge up thecontainer bottom to urge the container to an erected position.
 103. Themethod of claim 102 further comprising injecting a stream of compressedair into the open end of the container and towards the container bottomfor assisting in the erecting.
 104. An automated device for erecting anindividual portion unerected French fry container of the type havingopposed sidewalls connected by a collapsible container bottom,comprising: an automated retrieving and container grasping device forgrasping one of the opposed sidewalls of the unerected container; arestraining member for restraining from relative movement the other ofsaid opposed sidewalls when said one sidewall is grasped by the graspingdevice and moved in the desired direction; means for causing relativemovement of the grasping device away from the restraining member whilethe grasping device grasps the unerected carton for causing the opposedcarton sidewalls to move apart from each other.
 105. The device of claim104 further comprising an urging member for urging the carton bottomupwardly during the movement apart of the carton sidewalls.
 106. Thedevice of claim 104 wherein said grasping device comprises a suction cupfor grasping one of the opposed container sidewalls.
 107. The device ofclaim 106 wherein said grasping device comprises a vacuum source toapply at least a partial vacuum to the suction cup.
 108. The device ofclaim 105 wherein said urging member comprises an inclined ramp. 109.The device of claim 104 further comprising means for injecting a streamof compressed air into the open end of the container when the opposedsidewalls are at least partially moved apart from each other to helpurge the opposed sidewalls apart in erecting the container.
 110. Thedevice of claim 104 further comprising a carriage on which said graspingdevice is mounted for causing linear movement of said grasping device ina first dimension.
 111. The device of claim 110 further comprising asecond carriage for linear movement of said grasping device in a seconddimension.